Materials and methods for manufacturing cigarettes

ABSTRACT

Cigarettes are manufactured using modified automated cigarette making apparatus. Those cigarettes possess smokable rods having paper wrapping materials having additive materials applied thereto as patterns. The additive material can be applied as a coating formulation in an off-line manner to a continuous paper sheet web that is later used for cigarette manufacture. The additive material can be applied as a coating formulation in an on-line manner to continuous paper web moving through an operating cigarette making machine. The coating formulation is applied to the paper web using roll applicator techniques, ink jet printing techniques or electrostatic precipitation techniques. Liquid coating formulation are curable, and are virtually absent of solvent or liquid carrier. Radiation, such as ultraviolet or electron beam radiation, is used to solidify and fix polymerizable liquid components of the coating formulation that have been applied to the paper web. Heating and subsequent cooling of the coating formulation used to fix solid components of the coating formulation that have been applied to the paper web. Registration techniques are used to ensure proper positioning of the additive material on the smokable rods so manufactured, and to ensure proper quality of those cigarettes.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Divisional application of, and claims benefit of,U.S. patent application Ser. No. 10/440,219, filed on May 16, 2003,which is incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The present invention relates to smoking articles, and in particular, toequipment, materials and techniques used for the manufacture of thosesmoking articles and components thereof. More specifically, the presentinvention relates to the manufacture of cigarette rods, and inparticular, to systems and methods for applying an additive material todesired locations of wrapping materials of cigarettes in an efficient,effective and desired manner.

BACKGROUND OF THE INVENTION

Smoking articles, such as cigarettes, have a substantially cylindricalrod-shaped structure and include a charge, roll, or column of smokablematerial, such as shredded tobacco, surrounded by a paper wrapper, toform a “cigarette rod,” “smokable rod” or a “tobacco rod.” Normally, acigarette has a cylindrical filter element aligned in an end-to-endrelationship with the tobacco rod. Typically, a filter element comprisesplasticized cellulose acetate tow circumscribed by a paper materialknown as “plug wrap.” Certain cigarettes incorporate filter elementscomprising, for example, activated charcoal particles. Typically, thefilter element is attached to one end of the tobacco rod using acircumscribing wrapping material known as “tipping paper.”

A cigarette is used by a smoker by lighting one end of that cigarette,and burning the tobacco rod. The smoker then receives mainstream smokeinto his or her mouth by drawing on the opposite end of the cigarette.During the time that the cigarette is not being drawn upon by thesmoker, the cigarette remains burning.

Numerous attempts have been made to control the manner that a cigaretteburns when the cigarette is not being drawn upon. For example, cigarettepapers have been treated with various materials to cause cigarettesincorporating those papers to self extinguish during periods when thosecigarettes are lit but are not being actively puffed. Certain treatmentmethods have involved applying materials to the paper in circumferentialbands or longitudinal stripes, creating areas that affect the burn rateof cigarettes incorporating those cigarette papers. See, for example,U.S. Pat. No. 3,030,963 to Cohn; U.S. Pat. No. 4,146,040 to Cohn; U.S.Pat. No. 4,489,738 to Simon; U.S. Pat. No. 4,489,650 to Weinert; andU.S. Pat. No. 4,615,345 to Durocher; US Patent Application 2002/0185143to Crooks et al.; and U.S. patent application Ser. No. 09/892,834, filedJun. 27, 2001. In addition, numerous references disclose applying filmsto the paper wrapping materials of tobacco rods. See, for example, U.S.Pat. No. 1,909,924 to Schweitzer; U.S. Pat. No. 4,607,647 to Dashley;and U.S. Pat. No. 5,060,675 to Milford et al.

“Banded” paper wrapping materials that are used for cigarettemanufacture possess segments defined by the composition, location, andproperties of the various materials within those wrapping materials.Numerous references contain disclosures suggesting various bandedwrapping material configurations. See, for example, U.S. Pat. No.1,996,002 to Seaman; U.S. Pat. No. 2,013,508 to Seaman; U.S. Pat. No.4,452,259 to Norman et al.; U.S. Pat. No. 5,417,228 to Baldwin et al.;U.S. Pat. No. 5,878,753 to Peterson et al.; U.S. Pat. No. 5,878,754 toPeterson et al.; and U.S. Pat. No. 6,198,537 to Bokelman et al.; and PCTWO 02/37991 and PCT WO 03/034845. Methods for manufacturing banded-typewrapping materials also have been disclosed. See, for example, U.S. Pat.No. 4,739,775 to Hampl, Jr. et al.; and U.S. Pat. No. 5,474,095 to Allenet al.; and PCT WO 02/44700 and PCT WO 02/055294. Some of thosereferences describe banded papers having segments of paper, fibrouscellulosic material, or particulate material adhered to a paper web.See, U.S. Pat. No. 5,263,999 to Baldwin et al.; U.S. Pat. No. 5,417,228to Baldwin et al.; and U.S. Pat. No. 5,450,863 to Collins et al.; andU.S. Patent Application 2002/0092621 to Suzuki. Methods formanufacturing cigarettes having treated wrapping materials are set forthin U.S. Pat. No. 5,191,906 to Myracle, Jr. et al. and PCT WO 02/19848.

Additive materials can be applied to cigarette paper wrapping materialsprior to the time that those wrapping materials are used for cigarettemanufacture (i.e., in a so-called “off-line” fashion). For certainadditive material components (e.g., ethylcellulose) that are appliedoff-line, it has been desirable for additive materials to be appliedwithin non-aqueous solvents, such as iso-propyl acetate. See, forexample, U.S. patent application Ser. No. 10/303,648, filed Nov. 25,2002, which is incorporated herein by reference in its entirety.Additive materials also can be applied to cigarette paper wrappingmaterials during the time that those wrapping materials are used forcigarette manufacture (i.e., in a so-called “on-line” fashion). Forcertain additive material components (e.g., starch-based materials) thatare applied on-line, it has been desirable for additive materials to beapplied as water-based formulations. See, for example, U.S. patentapplication Ser. No. 10/324,837, filed Dec. 20, 2002, which isincorporated herein by reference in its entirety.

It would be highly desirable to provide cigarettes having predeterminedpatterns of additive materials (e.g., as bands) applied to the wrappingmaterials of those cigarettes. It would be particularly desirable toapply additive materials to a continuous web of a wrapping material of atobacco rod of a cigarette in an efficient and effective manner duringthe manufacture of that tobacco rod. It also would be desirable toprovide a method for minimizing or avoiding the use of solvents whenapplying additive material to the wrapping material; and it also wouldbe desirable that such method operate effectively and be easilyimplemented within a conventional automated cigarette making machine ofthe type used to produce commercial quantities of cigarettes.

SUMMARY OF THE INVENTION

The present invention provides systems, materials, apparatus, andprocesses for manufacturing smoking articles and components of thosesmoking articles. Of particular interest are systems, apparatus, andmethods for manufacturing cigarettes and wrapping materials used formanufacturing cigarettes. The present invention relates to manners andmethods for transferring additive material to, and for retaining anadditive material on, desired locations of a wrapping material (e.g.,paper wrapping web) suitable for use for smoking article manufacture.The additive material can be applied to the wrapping material, and thatwrapping material can be used at later times for the manufacture ofsmoking articles, such as cigarettes. Of particular interest is theapplication of additive material to wrapping material during manufactureof smoking articles using an automated cigarette making machine (e.g., amachine designed to produce a continuous cigarette rod). That is, it isof particular interest to apply and fix an additive material to acontinuously advancing strip of a paper web within a region of anautomated cigarette making machine using a component of such a machineduring a cigarette manufacturing process.

Certain cigarette making apparatus and systems are characterized assingle component systems. A continuous paper web is provided from asource (e.g., a bobbin) associated with a component of such a system(e.g., an unwind spindle assembly of that system). Tobacco filler andcomponents for manufacturing a continuous cigarette rod from the tobaccofiller and the continuous paper web are provided using the samecomponent of that system (e.g., using an upwardly moving air streamcoupled with a conveyor system and a garniture system, respectively).Such a cigarette making apparatus can be used to manufacture cigarettesfrom a continuous paper web that has been treated previously so thatadditive material (e.g., a coating formulation) has been applied to thatpaper web in an off-line fashion. Such a cigarette making apparatus alsocan be adapted to incorporate additive application apparatus that allowapplication of additive material to the continuous paper web in anon-line fashion.

Certain cigarette making apparatus and systems are characterized asmulti-component systems, and in particular, two component systems. Acontinuous paper web is provided from a source that is the firstcomponent of such a system. Tobacco filler and components formanufacturing a continuous cigarette rod from the tobacco filler and thecontinuous paper web supplied by the first component are provided usingthe second component of that system. For preferred two componentsystems, the two components are independent, stand alone units. Suchcigarette making apparatus can be adapted to incorporate additiveapplication apparatus that provide ways to apply additive material tothe continuous paper web in an on-line fashion.

Certain cigarette making apparatus and systems characterized asmulti-component systems can be three component systems. A continuouspaper web is provided from a source that is the first component of sucha system. A continuous paper web is supplied by the first component ofthe system, and the first component can be adapted to incorporate anadditive application apparatus in order that a coating formulation canbe applied to the paper web. Tobacco filler and components formanufacturing a continuous cigarette rod from the tobacco filler iscarried out using the second component of that system. The thirdcomponent of the system is positioned between the first and secondcomponents, and can be used to apply coating formulation to the paperweb that is supplied by the first component. The third component of thesystem also is adapted so that the continuous paper web passes from thatthird component to the second component of the system for cigarettemanufacture. For preferred three component systems, the three componentsare independent, stand alone units. Such a cigarette making apparatuscan be used to apply additive material to the continuous paper web in anon-line fashion.

Equipment and methods for applying additive material to a substrate,such as a continuous strip of paper web used as a wrapping material forcigarette manufacture, can be employed to apply additive material as apredetermined pattern to the paper web during operation of an automatedcigarette making machine. The additive material can be applied todesired locations on the paper web using suitably positioned andcontrolled application devices that can apply the additive material ineither a contact or non-contact manner. A contact application device isused to apply additive material to the paper web by transferring theadditive material from a surface of that device that involves an actionof physical touching of the some portion of that device with the paperweb. Contact application devices include roller-type applicator devices,screen printing devices, and the like. Non-contact or non-impactapplication devices are used to apply additive material to the paper webby projecting additive material from one region to the paper web, suchas is carried out using spraying techniques, electrostatic depositiontechniques, or the like.

In one aspect, the present invention relates to equipment and methodsfor applying an additive material to a substrate, such as a paper webused as a wrapping material for cigarette manufacture. Those equipmentand methods are particularly suitable in connection with the operationof an automated cigarette making machine, and for the purpose ofapplying a predetermined pattern of additive material to a continuousstrip of paper web. As such, a suitable method for applying additivematerial to a web of wrapping material, most preferably in an on-linefashion, is provided.

An additive application apparatus that can be used to apply varioustypes of additive materials having fluid forms to a continuouslyadvancing substrate, such as a moving strip of paper web within acigarette making machine, includes an outer housing and an inner gear.The outer housing is wheel-like, rotatable, and possesses an outersurface and an inner region. The inner region possesses (i) a reservoirfor additive material, (ii) an inner face possessing gear teeth, and(iii) a passageway for passage of fluid from the inner region to theouter surface. The inner gear is a rotatable gear having gear teeth, andis located within the housing. The gear teeth of the housing and theinner gear are in a cooperating arrangement with one another; that is,the gear teeth of the housing and inner gear are meshed in an operativearrangement. Rotation of the inner gear relative to the housing isdriven by a suitable power source. Rotation of the outer housing causesadditive material within the reservoir to be transferred to troughregions between adjacent gear teeth of the inner region of the outerhousing; that is, during rotation of the inner gear and outer housing,additive material is picked up on regions of the gear face of the outerhousing from the reservoir. Rotation of the inner gear also is such thatcooperation of the gear teeth of the rotatable gear and the housingcause additive material within trough regions between adjacent gearteeth of the outer housing to be forced through the passageways. Thatis, meshing of the gear teeth, and the configuration of meshed gearteeth in the region of each passageway, provide pumping action resultingin a forcing of the additive material carried within a trough regionbetween adjacent gear teeth of the outer housing through thosepassageways. Such an apparatus is used in conjunction with a cigarettemaking machine in order to apply an additive material having a fluidform to a continuous strip of paper web that is arranged so as to movepast that apparatus and contact a portion of the outer surface ofhousing. As such, additive material that is forced through thepassageways of the rotating housing is applied at desired locations onthe paper web. Preferred additive materials are applied as fluid coatingformulations, including those that are virtually free of solvents orliquid carriers, and those that incorporate solvents or liquid carriers(e.g., aqueous liquids).

Another additive application apparatus includes a first roller adaptedto receive the additive material (e.g., a coating formulation in liquidform) and a second roller adjacent to the first roller adapted totransfer the additive material from the first roller to a substrate(e.g., continuous advancing paper web). That apparatus also includes anadditive material reservoir adjacent to the first roller for containingthe additive material, and for supplying the additive material to thefirst roller. The additive material so supplied is positioned on theroll face of the first roller. For that apparatus, the roll faces ofprotruding dies extending from the second roller are in roll contactwith the roll face of the first roller in one location; and the rollfaces of the protruding dies of the second roller are in contact withthe paper web in another location; thus allowing for a predeterminedtransfer of additive material in a two-step manner. That is, when theadditive material is supplied to the roll face of the first roller, thatadditive material is transferred to the roll face of the protruding diesof the second roller; and when those dies possessing additive materialon their roll faces contact the advancing paper web, the additivematerial is transferred from the roll face of the protruding dies of thesecond roller and applied to the advancing paper web.

Another additive application apparatus includes a first roller adaptedto receive the additive material (e.g., a coating formulation in liquidform) and adapted to transfer the additive material to a substrate(e.g., a continuous advancing paper web). The paper web passes betweenthe roll faces of the first roller and a second roller. That apparatusalso includes an additive material reservoir adjacent to the firstroller for containing the additive material, and for supplying theadditive material to the first roller. The additive material so suppliedis positioned on the roll face of the first roller. For that apparatus,the roll faces of protrusions or cams extending from the second rollerare in roll contact with the roll face of the first roller, and thepaper web passes between those roll faces such that both rollers areperiodically in contact with the paper web; thus allowing for apredetermined transfer of additive material to the paper web from theroll face of the first roller when the roll faces of the protruding camsof the second roller cause the application of force to the paper web.That is, when the additive material is supplied to the roll face of thefirst roller, that additive material is transferred to pre-determinedlocations on the surface of the paper web when the protruding cause ofthe second roller cause the paper web to be pushed against the roll faceof the first roller.

An additive material, which can have the form of a coating formulation,is applied to a paper wrapping material for cigarette manufacture.Certain preferred coating formulations that are applied to wrappingmaterials (e.g., paper webs) incorporate relatively low levels ofsolvent or liquid carrier. Highly preferred coating formulations areessentially absent of solvent or liquid carrier, and most highlypreferred coating formulations are virtually free of solvent or liquidcarrier. Representative additive application techniques that are usefulfor applying generally liquid type coating formulations, or those typesof formulations having the form of liquid dispersions, can involve theuse of either contact types of printing devices (e.g., roll applicators)or non-contact digital printing types of application systems (e.g., inkjet type printing devices). Representative additive applicationtechniques that are useful for applying coating formulations havinggenerally solid forms can involve the use of non-contact printing typesof application systems, such as electrostatic deposition type printingdevices.

A wrapping material having coating formulation applied thereto can besubjected to processing steps that cause certain components of thatformulation to form a type of film that is in intimate contact with thatwrapping material. Typically, a fluid coating formulation incorporatingan aqueous solvent or liquid carrier is applied to the paper wrappingmaterial and is subjected to exposure conditions sufficient to evaporatethat solvent or liquid carrier; and hence provide a dry film that isfixed in intimate contact with the paper. Typically, a coatingformulation incorporating pre-polymer components (that typically have afluid form) is applied to the paper wrapping material and is subjectedto exposure to suitable radiation (e.g., ultraviolet or electron beamradiation), of a type and in a manner sufficient, to cause thepre-polymer components to undergo polymerization and hence solidify(e.g., be cured); and hence the resulting polymer forms a solid type offilm that is fixed in intimate contact with the paper. Alternatively, acoating formulation incorporating finely divided solid form componentsis applied to the paper wrapping material (e.g., using electrostaticdeposition techniques) and is subjected to further processing conditions(e.g., the application of heat followed by cooling) so as to causecertain components of that formulation to form a film which thensolidifies; and hence the resulting polymeric film is fixed (e.g.,fused) in intimate contact with the paper. Preferably, the coatingformulation is applied to a continuous advancing strip of paper web, andthe resulting coated paper web is used as wrapping material for smokablematerial (e.g., for the manufacture of a cigarette rod).

A registration system can control, in an on-line fashion, the locationof the applied pattern (e.g., bands) of additive material on thewrapping material to the location of that pattern on the smoking articlethat is manufactured. The application of each band can be controlledrelative to the speed at which the cigarette making machine is operated;and the location of each band can be timed to the operation of theadditive applicator system and to the operation of the cutting device(e.g., flying knife) that cuts the continuous rod into cigarette rods ofpredetermined length. In addition, a servo control system incorporatinga multi-axes programming unit can be used to facilitate adjustmentsresulting from changes in the length the paper web during travel betweenthe applicator system and the cutting device.

An inspection system can be used to ensure the quality of the treatedpaper web and the smoking articles manufactured therefrom. The systempossesses a detector (e.g., a capacitance detector) for detectinginformation regarding the electrical properties of the web, and forgenerating responsive electrical signals. The system further includescircuitry for processing those electrical signals to determineinformation relating to the presence of the pattern on the web, and forgenerating output signals. The system further includes computing logicfor receiving the output signals and for determining whether thosesignals are representative of an unacceptable, irregular pattern on theweb or of an acceptable, desired pattern. The system further includescomputer logic for receiving information regarding irregular patternsand for signaling rejection of component materials (e.g., formedcigarettes) manufactured from wrapping materials possessing that havebeen determined to possess irregular patterns.

As will be appreciated by those of ordinary skill in the art, thepresent invention has wide utility in a number of applications asillustrated by the variety of features and advantages discussed herein.As will be realized by those of skill in the art, many differentembodiments of the foregoing are possible. Additional uses, objects,advantages, and novel features of the present invention are set forth inthe detailed description that follows and will become more apparent tothose skilled in the art upon examination of the following disclosure orby practice of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a portion of a cigarette makingmachine showing a source of wrapping material, a source of tobaccofiller and a garniture region that is used to produce a continuouscigarette rod.

FIG. 2 is a schematic illustration of a cigarette making machineassembly including the combination of a wrapping material supply systemand a cigarette making machine.

FIG. 3 is a schematic illustration of a cigarette making machineassembly for carrying out certain aspects of the present invention, theassembly including the combination of a wrapping material supply systemand a cigarette making machine.

FIG. 4 is a schematic illustration of a cigarette making machineassembly for carrying out certain aspects of the present invention, theassembly including the combination of a wrapping material supply systemand a cigarette making machine.

FIG. 5 is a perspective of a representative additive applicatorapparatus, that apparatus being mounted at an appropriate location on acigarette making machine assembly.

FIG. 6 is an exploded perspective of an additive applicator apparatus ofthe type shown in FIG. 5.

FIG. 7 is a schematic illustration of a representative additiveapplicator apparatus.

FIG. 8 is an exploded perspective of an additive applicator apparatus ofthe type shown in FIG. 7.

FIG. 9 is a schematic illustration of a representative additiveapplicator apparatus.

FIG. 10 is a perspective of an additive applicator apparatus forcarrying out certain aspects of the present invention.

FIG. 11 is a schematic illustration of an end view of an additiveapplicator apparatus of the type shown in FIG. 10.

FIG. 12 is a cross-sectional schematic illustration of side view anadditive applicator apparatus of the type shown in FIG. 10 taken alonglines 12-12 in FIG. 11.

FIG. 13 is a perspective of an additive applicator apparatus forcarrying out certain aspects of the present invention.

FIG. 14 is a schematic illustration of an end view of an additiveapplicator apparatus of the type shown in FIG. 13.

FIG. 15 is a cross-sectional schematic illustration of side view anadditive applicator apparatus of the type shown in FIG. 13 taken alonglines 15-15 in FIG. 14.

FIG. 16 is a schematic illustration of a representative additiveapplicator apparatus.

FIG. 17 is a schematic illustration of a representative additiveapplicator apparatus.

FIG. 18 is a schematic illustration of a representative additiveapplicator apparatus.

DETAILED DESCRIPTION

Aspects and embodiments of the present invention include cigarettemaking machines and components thereof that are useful for manufacturingcigarettes, and in particular, that are useful for transferring andretaining additive material on a paper wrapping web in an efficient,effective and desired manner. FIGS. 1 through 18 illustrate thoseaspects and embodiments. Like components are given like numericdesignations throughout the figures.

A conventional automated cigarette rod making machine useful in carryingout the present invention is of the type commercially available fromMolins PLC or Hauni-Werke Korber & Co. KG. For example, cigarette rodmaking machines of the type known as Mk8 (commercially available fromMolins PLC) or PROTOS (commercially available from Hauni-Werke Korber &Co. KG) can be employed, and can be suitably modified in accordance withthe present invention. A description of a PROTOS cigarette makingmachine is provided in U.S. Pat. No. 4,474,190 to Brand, at col. 5, line48 through col. 8, line 3, which is incorporated herein by reference.Types of equipment suitable for the manufacture of cigarettes also areset forth in U.S. Pat. No. 4,844,100 to Holznagel; U.S. Pat. No.5,156,169 to Holmes et al. and U.S. Pat. No. 5,191,906 to Myracle, Jr.et al.; and PCT WO 02/19848. Designs of various components of cigarettemaking machines, and the various materials used to manufacture thosecomponents, will be readily apparent to those skilled in the art ofcigarette making machinery design and operation.

Referring to FIG. 1, a one-component cigarette making machine assembly 8includes cigarette making machine 10. The cigarette making machine 10includes a chimney region 16 that provides a source of tobacco filler20, or other smoking material. The tobacco filler 20 is providedcontinuously within an upwardly moving air stream (shown by arrow 22),and is blown onto the lower outside surface of a continuous a conveyorsystem 28. The conveyor system 28 includes an endless, porous, formableconveyor belt 32 that is supported and driven at each end by left roller36 and right roller 38. A low pressure region or suction chamber 41within the foraminous belt 32 acts to attract and retain tobacco filler20 against the bottom of the conveyor system 28. As such, tobacco filler20 located below the conveyor belt 32 is pulled upward toward that belt,thereby forming the tobacco filler into a tobacco stream or cake on thelower surface of that belt. The conveyor belt 32 thus conveys the streamof tobacco filler 20 to the left; toward a garniture section 45 of thecigarette making machine 10. An ecreteur or trimmer disc assembly 48assists in providing transfer of the appropriate amount of tobaccofiller 20 to the garniture region 45. Descriptions of the components andoperation of several types of chimneys, tobacco filler supply equipmentand suction conveyor systems are set forth in U.S. Pat. No. 3,288,147 toMolins et al.; U.S. Pat. No. 4,574,816 to Rudszinat; U.S. Pat. No.4,736,754 to Heitmann et al. U.S. Pat. No. 4,878,506 to Pinck et al.;U.S. Pat. No. 5,060,665 to Heitmann; U.S. Pat. No. 5,012,823 to Keritsiset al. and U.S. Pat. No. 6,360,751 to Fagg et al.

Meanwhile, a continuous web of paper wrapping material 55 is suppliedfrom a bobbin 58. The bobbin is supported and rotated using an unwindspindle assembly 59.

The paper web 55 is routed on a desired path using a series of idlerrollers and guideposts (shown as rollers 60, 61), through an optionalprinting assembly device 65, and ultimately through the garniture region45. Typically, product indicia are printed onto the paper web 55 atpredetermined regions thereof using printing assembly 65. Printingassemblies for printing product indicia (e.g., logos in gold coloredprint) are component parts of commercially available machines, and theselection and operation thereof will be readily apparent to thoseskilled in the art of cigarette making machine design and operation.Techniques for registering the location of printed product indicia onthe ultimate cigarette product (e.g., on the paper wrapper of acigarette rod in a location immediately adjacent to the tipping materialof that product) are known to those skilled in the art of automatedcigarette manufacture.

The paper web 55 also is routed through an applicator system 70 prior tothe time that the web reaches the garniture section 45. The applicatorsystem 70 is employed to apply a desired pattern of additive material 73to the paper web 55. A representative pattern is provided by applyingspaced bands that are aligned transversely to the longitudinal axis ofthe paper web 55. A representative additive material 73 is a coatingformulation having a fluid form; and representative coating formulationsthat have fluid forms can have the form of liquids, syrups, pastes,emulsions, or dispersions or slurries of solid materials within any ofthe foregoing.

Optionally, the paper web 55 can be routed through a heating/coolingcontrol unit (not shown) immediately before the paper web passes throughthe applicator system 70. A suitable heating/cooling unit is a heatingunit having the form of an infrared heater (not shown), and that heatercan be operated at any desired temperature; for example, at atemperature of about 180° C. to about 220° C. The heating/cooling unitcan be used to provide the paper web 55 at a desired temperature (e.g.,the paper web can be pre-heated) immediately prior to application of theadditive material formulation 73 to the surface of that paper web.

A representative additive applicator 70 is a contact-type applicatorthat comprises a pick-up roller 78 and a transfer roller 82. The pick-uproller 78 includes a plurality of patterned (e.g., evenly spaced apart)pockets on its roll face (not shown) into which a predetermined amountof additive is deposited. The positioning, shape and number of pocketscan vary, and typically depends upon the pattern that is desired to beapplied to the paper web 55 (e.g., spaced apart pockets can be used toplace spaced bands of additive material 73 on the web). For example, inone embodiment of a transfer roller 82, seven pockets each having theform of transversely aligned bands each placed about 46 mm apart. Theshape, including depth, of each pocket can determine the amount ofadditive material that can be carried by that pocket, and hence appliedto the paper web 55.

The additive material 73 typically is provided from a supply sourcereservoir (not shown) through tubing or other suitable supply means (notshown) to a port or supply region 85 near the head (i.e., infeed region)of the pick-up roller 78. The additive material 73 is fed from the headof the pick-up roller into the pockets of the pick-up roller.

If desired, the supply region and the region of the pick-up roller 78,and other relevant regions of the additive applicator 70, can besupplied with heat control system using a suitable heating or coolingdevice (not shown). As such, a heating device can provide a heatedregion that can be used to assist in maintaining a solid or very viscouscoating formulation in a melted form or fluid form (e.g. the form of aliquid, a syrup, a paste, an emulsion, or a dispersion or slurry ofsolid materials within any of the foregoing). A representative heatingdevice is an electrical resistance heating unit controlled by arheostat; and the heating device can be appropriately fashioned so as totransfer the desired amount of heat to the various components of theadditive applicator 70. As such, sufficient heat can be provided toprovide coating formulation at a temperature above ambient temperature,and for example, at a temperature within the range of about 120° F. toabout 180° F. If desired, heat insulation material (not shown) can bepositioned in adjacent regions of the cigarette making machine 10 inorder that transfer of heat to other regions of that machine isminimized or prevented.

Operation of the pick-up roller 78 and the transfer roller 82 are timedand controlled relative to the speed of operation of the cigarettemaking machine 10. As the pick-up roller 78 and the transfer roller 82are engaged in roll contact, and rotate in contact with each other in acontrolled manner, the additive material 73 is transferred from thepockets of the pick-up roller 78 onto predetermined regions of the rollface surface (not shown) of the transfer roller 82. The additivematerial 73 is transferred onto the transfer roller 82 surface inessentially the same pattern as that of the spaced apart pockets on thepick-up roller 78 (i.e., the pattern applied to the paper web isdictated by the design of the pattern of the roll face of the pick-uproller 78).

Representative types of contact-type applicators are described ingreater detail hereinafter with reference to FIGS. 5 through 17. Thosetypes of applicators can be suitably incorporated into the cigarettemaking machine assembly 8.

The paper web 55 comprises two major surfaces, an inside surface 88 andan outside surface 90. The stream of tobacco filler 20 ultimately isdeposited upon the inside surface 88 of the paper web 55, and theadditive material 73 most preferably also is applied to the insidesurface 88 of that web. As the paper web 55 travels across the surfaceof the rotating transfer roller 82, the additive material 73 on thesurface of the transfer roller 82 is transferred to the inside surface88 of the advancing paper web 55 at locations corresponding to thelocation of the pockets located on the roll face of the pick-up roller78.

After the additive material 73 has been applied to the paper web 55, theweb can be exposed to a sensor or detector 95 for a measurement system,such as an inspection system (not shown). Preferably, the detector 95 ismounted on the frame of the cigarette making machine 10 and ispositioned so as to receive information concerning the paper web 55immediately after additive material 73 has been applied to that paperweb. Typically, the detector 95 is a component of certain registrationsystems and inspection systems. Types of sensors, detectors andinspection system components and description of inspection systemtechnologies and operation thereof are set forth in U.S. patentapplication Ser. No. 10/324,837, filed Dec. 20, 2002. Alternativesensors, detectors and inspection system components and description ofinspection system technologies and methods of operation are set forth inU.S. Pat. No. 4,845,374 to White et al.; U.S. Pat. No. 5,966,218 toBokelman et al.; U.S. Pat. No. 6,020,969 to Struckhoff et al. and U.S.Pat. No. 6,198,537 to Bokelman et al.; which are incorporated herein byreference.

A representative inspection system employs a capacitance detectorpositioned downstream from the applicator system 70. A preferreddetector is a non-contact detector that can sense changes in thedielectric field of the paper web resulting from the application ofadditive material to certain regions of that paper web. A representativedetector is a Hauni Loose End Detector, Part Number 2942925CD001500000that is available from Hauni-Werke Korber & Co. KG. The detector iscombined with appropriate electronics for signal processing. That is,the detector generates an electrical signal, and appropriate electroniccircuitry is used to compare that signal relative to a programmedthreshold level. Such a signal allows for graphical display of theprofile of applied additive material along the length of the paper web.When application of a band of additive material does not occur asdesired (i.e., a band is missing on the paper web, or the amount ofadditive material that is applied is not the desired amount) a signal isgenerated. As such, rejection of poor quality rods, and adjustments tothe overall operation of the cigarette making machine, can occur. Inaddition, an output signal from such a measurement system can be used ina feedback control system to maintain the desired level of additivematerial to the paper web and/or to maintain the desired rate of feed ofcoating formulation to the applicator system.

Additionally, after the additive material 73 has been applied to thepaper web 55, the web can be passed through an optional heating/coolingcontrol device 120. The control device 120 can be used to alter the heatto which the paper web 55 and additive material 73 is subjected (e.g.,by raising or lowering temperature). For example, the heating/coolingcontrol device can be a heating or drying device adapted to assist inthe removal of solvent (e.g., moisture) from the additive material 73that has been applied to the paper web 55. Alternatively, for example,the heating/cooling control device can be a cooling device adapted toassist in the hardening melted additive material 73 that has beenapplied to the paper web 55 using a heated additive applicator system70. Typically, the heating/cooling control device 120 has a tunnel-typeconfiguration through which the paper web 55 is passed; and during thetime that the paper web is present within that tunnel region, the paperweb is subjected to heating supplied by a convection or radiant heatingdevice, or cooling supplied by a refrigerant-type, solid carbondioxide-type or liquid nitrogen-type cooling device.

Typically, the region of the cigarette making machine 10 where theheating/cooling device 120 is located does not afford sufficient room toprovide a heating/cooling control device 120 of any appreciable size.For this reason, it is desirable to locate such an optionalheating/cooling device 120 in a location that is offset from thecigarette making machine. For example, appropriately located andpositioned turning bars (not shown) can be used to direct the paper web55 outward (and optionally upward or downward) from the front face ofthe cigarette making machine 10, and the paper web 55 can be routedthrough the heating/cooling device 120 that can be supported but frameor other suitable support means (not shown), and appropriately locatedand positioned turning bars (not shown) can be used to direct the paperweb 55 so subjected to heating or cooling back to the cigarette makingmachine 10 for continued use in the cigarette manufacturing process.

The paper web 55 having certain types of additive materials 73 appliedthereto is subjected to exposure to appropriate radiation. That is,coating formulations incorporating pre-polymer components can be exposedto suitable radiation of a type and in a manner sufficient to cause thepre-polymer components to undergo polymerization reactions and hencesolidify. At least one radiation source 122 is positioned so as tosubject the paper web 55 having additive material applied thereto toexposure to radiation. Typical radiation sources can provide radiation,for example, in the ultraviolet (uv) range or radiation in the form ofelectron beam radiation (i.e., gamma radiation). For paper web havingpre-polymer components (not shown) applied thereto, heating/coolingcontrol device 120 also can be replaced with a source of radiation, inorder to provide for exposure of the coating formulation on the paperweb to radiation that causes polymerization (and hence solidification)of the additive material. A reflective shield or cover (not shown) canbe positioned over that radiation source 122 in order to ensure thatradiation is directed toward the coating formulation positioned on thepaper web, and in order to minimize or prevent emission of radiation toundesired locations within the environment near the cigarette makingmachine assembly 8. If desired, the atmosphere within the shield orcover (not shown) can be controlled (e.g., by flushing the region withdry nitrogen gas).

Optionally, though not preferably, the indicia printing assembly 65 canbe modified in order to print formulations other than printing inks andintended for purposes other than product indicia. For example, theprinting assembly 65 can be adapted to apply coating formulations havingintended purposes other than product indicia. For example, fluid coatingformulations (e.g., that incorporate pre-polymer components and areessentially absent of solvent, or that are water-based), can be appliedto either the inside surface or outside surface of the paper web 55,using a suitably adapted printing assembly 65. Such coating formulationscan be supplied using a pump or other suitable means (not shown) from areservoir (not shown) through a tube or other suitable supply means (notshown). The paper web 55 having water-based additive material (notshown) applied thereto is subjected to exposure to heat or microwaveradiation using heat source 126, in order to dry the coating formulationand fix additive material to the desired location on the paper web. Forpaper web having pre-polymer components (not shown) applied thereto, theheat source 126 is replaced with a source of suitable radiation, inorder to provide for exposure of the coating formulation on the paperweb to radiation that causes solidification of the additive material. Areflective shield or cover (not shown) can be positioned over thatradiation source 126. The previously described heating/cooling controldevice 120 and/or the radiation source 122 also can be employed.

The paper web 55 travels toward the garniture region 45 of the cigarettemaking machine 10. The garniture region 45 includes an endless formablegarniture conveyor belt 130. That garniture conveyor belt 130 conveysthe paper web 55 around a roller 132, underneath a finger rail assembly140, and advances that paper web over and through a garniture entrancecone 144. The entrance cone 144 also extends beyond (e.g., downstreamfrom) the finger rail assembly 140. The right end of the garnitureconveyor belt 130 is positioned adjacent to and beneath the left end ofthe suction conveyor system 28, in order that the stream of tobaccofiller 20 carried by conveyor belt 32 is deposited on the paper web 55in that region. The finger rail assembly 140 and garniture entrance cone144 combine to provide a way to guide movement of an advancing tobaccofiller cake 20 from the suction conveyor 32 to the garniture region 45.Selection and use of finger rail assemblies and garniture entrance coneswill be readily apparent to those skilled in the art of cigarettemanufacture. Alternatively, it is possible to employ those finger railassemblies and/or modified garniture entrance cones that are set forthin U.S. patent application Ser. No. 10/324,837, filed Dec. 20, 2002.

As the conveyor belt 32 and tobacco filler cake 20 travel within thefinger rail assembly 140, vacuum suction applied to the inside region ofthe conveyor belt 32 is released. As a result, tobacco filler 20 isreleased from contact with the conveyor belt 32, falls downwardly fromthat conveyor belt through a longitudinally extending track (not shown)within the finger rail assembly 140, and is deposited onto the advancingpaper web 55 at the left side of the garniture region 45 immediatelybelow the finger rail assembly. In conjunction with the release ofvacuum from the conveyor belt 32, removal of tobacco filler 20 from theconveyor belt 32 and deposit of that tobacco filler onto the movingpaper web 55 is facilitated through the use of a shoe or scrape 155 orother suitable means, that is used to peel or otherwise physicallyremove advancing tobacco filler 20 off of the outer surface of theextreme left end of the conveyor belt 32.

The garniture section 45 includes a tongue 160 adjacent to the distalend of the finger rail assembly 140 and above the top surface of thegarniture conveyor belt 130. The tongue 160 provides a commencement ofconstriction of the tobacco filler 20 that has been deposited on thepaper web 55. Meanwhile, the garniture conveyor belt 130 begins to formthat tobacco filler stream and paper web 55 into a continuous rod 170.The tongue 160 extends to a point where the paper web 55 is securedaround that stream of tobacco filler. The tongue 160 and the garnitureconveyor belt 130 define a passage which progressively decreases incross-section in the direction of movement of the tobacco filler stream,such that the deposited tobacco filler stream progressively forms asubstantially circular cross-section that is desired for the ultimatefinished continuous cigarette rod 170.

The garniture section 45 also includes a folding mechanism 180 on eachside of the garniture conveyor belt 130 located adjacent to, anddownstream from, the tongue 160. The folding mechanism 180 is aligned inthe direction of filler stream movement, further compresses the tobaccofiller 20 within the rod that is being formed, and folds the paper web55 around the advancing components of the forming continuous cigaretterod 170. A fashioned continuous tobacco rod that exits the tongue 160and folding mechanism 180 then passes through an adhesive applicator184, in order that adhesive is applied to the exposed length or lap seamregion of the paper web 55 (i.e., side seam adhesive is applied to thepaper web). That is, the exposed length of paper web 55 then is lappedonto itself, and the adhesive is set that region in order to secure thepaper web around the tobacco filler 20, thereby forming the continuouscigarette rod 170. The continuous rod 170 passes through a cutting orsubdivision mechanism 186 and this subdivided into a plurality of rods190, 191 each of the desired length. The selection and operation ofsuitable subdivision mechanisms 186, and the components thereof, will bereadily apparent to those skilled in the art of cigarette manufacture.For example, the cutting speed of knife (not shown) within a ledger orother suitable guide 192 is controlled to correspond to the speed thatthe cigarette making machine 10 is operated. That is, the location thatan angled flying knife (not shown) cuts the continuous rod 170 into aplurality of rods 190, 191, each of essentially equal length, iscontrolled by controlling the speed of operation of that knife relativeto speed that the cigarette making machine supplies the continuous rod.

Typically, operation of the conveyor belt 32, garniture belt 130 andflying knife (not shown) within ledger 192 all are mechanically linkedto one another by belts or other suitable means, and are driven off ofthe same power source (not shown). For example, for a cigarette makingmachine, such as a PROTOS 80 that is commercially available fromHauni-Werke Korber & Co. KG, the main motor of that cigarette makingmachine is used to drive operation of the conveyor belt 32, thegarniture belt 130 and the flying knife. An alternate design of such atype of cigarette making machine can be provided by providing power tothe flying knife from one power source, such as the motor of a servosystem (not shown); and the power to the garniture belt 130 and theconveyor belt 32 can be provided from a second power source, such as themotor of a second servo system (not shown). Typically, power foroperation of the garniture belt 130 is provided by suitable mechanicalconnection to the second power source, and the power for operation ofthe conveyor belt 32 is provided by suitable linkage to the operation ofthe garniture belt by suitably adapted timing belt systems, or othersuitable means (not shown). Encoders (not shown) mechanically coupled tothe first and second servo systems (not shown) provide information to aprocessing unit (not shown) regarding cigarette manufacturing speed, andgarniture speed, respectively. The detector 95 (e.g., such as a noncontact ultrasonic detector) also can be adapted to provide informationregarding location of additive material 73 that has been applied to thepaper web 55 to the same processing unit (not shown). Using theprocessing unit, the positioning of applied pattern on the paper web 55can be compared to a specified positioning of the pattern, and theprocessing unit can be used to alter the speed of operation of the twoservo systems relative to one another to bring cigarette rods 190, 191that are out of specification back to within specification. For example,the speed of operation of the flying knife can be increased and/or thespeed of operation of the garniture belt can be decreased untilcigarette rods are determined to be back within the desired range oftolerance or within specification.

Servo control systems and the operation thereof will be readily apparentto those skilled in the art of cigarette making machine design andoperation. Representative servo systems are readily available as SingleAxis Controller P/N: DKC03.3-040-7FW/FWA-EDODR3-FGP-04VRS-MS, Motor P/N:MKD025-144-KP1-KN SERVO MOTOR from Indramat; Ultra 5000 Single Axis P/N:2098-IPD-010 Motor P/N: Y-2012-1-H00AA from Allen Bradly; and Servo P/N:SC752A-001-01 Motor P/N: R34-GENA-HS-NG-NV-00 from Pacific Scientific.

Information concerning the position and speed of operation of the flyingknife can be fed to a servo control system that incorporates amulti-axes programming unit. Such a servo system is available asPPC-R02-2N-N-N1-V2-NN-FW from Indramat. As such, the servo system can beused to observe and control the transfer roller to a known positionrelative to the flying knife. Preferred cigarette making machines, suchas PROTOS machines, can possess an automatic servo-driven printdisplacement control systems as well as servo-driven paper tensioncontrol systems. Thus, the distance of travel of the paper web betweenthe applicator system and the continuous cigarette rod cutoff knife canbe changed; for example, when adjustments are made to correct for printdisplacement relative to the cut in the continuous rod or to controlpaper tension to avoid paper breakage. Such changes in distance oftravel of the paper web can vary; and for example, the changes of asmuch as 35 mm in paper travel can be provided for adjustments for printdisplacement, and changes of as much as 20 mm in paper travel can beprovided for paper tension adjustments. Thus, when any adjustments aremade that result in a change in the length of the path of travel of thepaper web from the applicator roller to the flying knife, the multi-axescontrol system can be used to make the corresponding adjustments to thespeed of operation of the applicator roller. Most preferably,adjustments to the speed of operation of the applicator roller areprovided at times when the applicator roller is not in the process ofapplying additive material to the paper web. As such, adjustmentsprogrammed to occur between the application of successive bands resultin avoiding smearing of additive material on the paper web and inavoiding paper breakage. To minimize the number of reject cigarettes,adjustments can be made on a single rod resulting in only a singlerejected rod, or adjustments can be made as small changes spread outover a number of cigarette rods until the application system in adjustedto be back to providing cigarettes having patterns applied at thedesired locations.

Those cigarette rods 190, 191 then most preferably have filter elements(not shown) attached thereto, using known components, techniques andequipment (not shown). For example, the cigarette making machine 10 canbe suitably coupled to filter tipping machine (not shown), such as amachine available as a MAX, MAX S or MAX 80 Hauni-Werke Korber & Co. KG.See, also, for example, U.S. Pat. No. 3,308,600 to Erdmann et al. andU.S. Pat. No. 4,280,187 to Reuland et al.

The cigarette making machine assembly and configuration described withreference to FIG. 1 are representative of a single cigarette makingmachine that provides both the tobacco filler and the patterned paperweb to the garniture region of that machine. Cigarette making machineassemblies and configurations representative of those that provide thetobacco filler to the garniture region from one location, and thepatterned paper web to the garniture region from another location (i.e.,multi-component systems), are described with reference to FIGS. 2, 3 and4.

Referring to FIG. 2, there is shown a two-component automated cigarettemaking machine assembly 8 that is constructed by coupling a wrappingmaterial supply machine 200 (e.g., a first component) with a cigarettemaking machine 10 (e.g., a second component).

A suitable wrapping material supply machine 200 can be provided byappropriately modifying a web supply unit available as SE 80 fromHauni-Werke Korber & Co. KG. See, for example, U.S. Pat. No. 5,156,169to Holmes et al., which is incorporated herein by reference. Othersuitable unwind units, such those having the types of components setforth in U.S. Pat. No. 5,966,218 to Bokelman et al., also can beemployed. The supply machine 200 most preferably is a free-standingmachine that is capable of providing a patterned web of wrappingmaterial 55 to a conventional (or suitably modified) cigarette makingmachine 10. The supply machine 200 includes a frame 205 that supports atleast one unwind spindle assembly 220 onto which a first bobbin 224 ismounted. Preferably, the supply machine 200 includes a second unwindspindle assembly 228 for a second bobbin (not shown), and a web splicingmechanism 232.

The paper web 55 is threaded through a tension sensor 236, which inconjunction with a braking component 239 connected to the shaft of theunwind spindle assembly, maintains a desired amount of tension on thepaper web 55 as it is transferred from the bobbin 224.

In operation, a continuous paper web 55 supplied from a bobbin 58 isrouted through a path defined by a series of idler rollers 245, 247,248, 249, 250 and guideposts 255, 256. The paper web 55 also is routedthrough an applicator system 70 that is used to apply a desired patternof additive material 73 to the paper web 55. Representative additivematerials 73 are coating formulations that have fluid forms can have theform of liquids, syrups, pastes, emulsions, or dispersions or slurriesof solid materials within any of the foregoing. Optionally, though notpreferably, the paper web can be routed through a heating/coolingcontrol unit (not shown) immediately before the paper web passes throughthe applicator system 70.

A representative additive applicator 70 comprises a pick-up roller 78and a transfer roller 82, and can be operated in essentially the samemanner as described previously with reference to FIG. 1. The additivematerial 73 typically is provided from a supply source reservoir (notshown) through tubing (e.g., Tygon-type tubing) or other suitable supplymeans (not shown) to a port or supply region 85 near the head (i.e.,infeed region) of the pick-up roller 78. If desired the supply regionand the region of the pick-up roller can be supplied with heat using asuitable heating device (not shown). The additive material 73 is fedfrom the head of the pick-up roller into the pockets of the pick-uproller. As the pick-up roller 78 and the transfer roller 82 are engagedin roll contact, and rotate in contact with each other, the additivematerial 73 is transferred from the pockets of the pick-up roller 78onto predetermined regions of the roll face surface (not shown) of thetransfer roller 82. The additive material 73 is transferred onto thetransfer roller 82 surface in essentially the same pattern as that ofthe spaced apart pockets on the pick-up roller 78 (i.e., the pattern onthe paper web is defined by that pattern on the roll face of the pick-uproller). Representative types of additive application systems aredescribed in greater detail hereinafter with reference to FIGS. 5through 17. The additive material 73 most preferably also is applied topredetermined locations on the inside surface 88 of the paper web 55.

After the additive material 73 has been applied to the paper web 55, theweb can be exposed to a sensor or detector 95 for a registration systemand/or an inspection system (not shown). Preferably, the detector 95 ispositioned so as to receive information concerning the paper web 55immediately after additive material 73 has been applied to that paperweb. Typically, the detector 95 is used in conjunction with the certainregistration systems and inspection systems, and in conjunction withsuitable marker components that are incorporated as components of theadditive material 73. Representative types of sensors, detectors andinspection system components and description of inspection systemtechnologies and operation thereof have been set forth hereinbefore withreference to FIG. 1. Components associated with registration andinspection also can be positioned elsewhere within the machine assembly8. The exact location of such components can depend upon operationalfactors, and the positioning such components can be a matter of designchoice.

Additionally, after the additive material 73 has been applied to thepaper web 55 (i.e., downstream from the applicator apparatus 70), theweb can be passed through an optional, heating/cooling control device280, or other suitable means for controlling heat to which the paper webis subjected. The control device 280 can be used to alter the heat towhich the paper web 55 and additive material is subjected (e.g., byraising or lowering the temperature). For example, the control devicecan be a heating or drying device adapted to assist in the removal ofsolvent (e.g., moisture) from the additive material 73 that has beenapplied to the paper web 55. Alternatively, for example, theheating/cooling control device can be a cooling device adapted to assistin the hardening melted additive material 73 that has been applied tothe paper web 55 using a heated additive applicator system 70.Typically, the heating/cooling control device 280 has a tunnel-typeconfiguration through which the paper web 55 is passed (through an inletend 282 and out an outlet end 283); and during the time that the paperweb is present within that tunnel region, the paper web is subjected toheating supplied using infrared convection or radiant heating devices,or cooling supplied using refrigerant-type, solid carbon dioxide-type orliquid nitrogen-type cooling devices.

The size of the heating/cooling device 280 can vary, particularlybecause that device is positioned and supported by a component 200 thatis physically separated from, and spaced from, the cigarette makingmachine 10. That is, there is provided sufficient room to subject thepaper web 55 to treatment using the heating/cooling device 280.Exemplary heating/cooling devices 280 have lengths of about 2 feet toabout 10 feet, with lengths of about 3 feet to about 8 feet beingtypical, and lengths of about 4 feet to about 7 feet being desirable.The distance that the paper web 55 travels through the heating/coolingdevice 280 (i.e., the length of travel through that device) can vary.For example, the paper web 55 can be routed back and forth within theheating/cooling device 280 using a suitably adapted roller systemconfiguration (not shown).

The heating/cooling control device 280 can be used to provide radiantheating to the paper web 55, and hence evaporate solvent (e.g., water)present in those coating formulations that are water-based. An exemplaryheating and drying system 280 is available as IMS Model No. P24N002KA022 kW, 2450 MHz Linear Drying System from Industrial Microwave Systems,Inc. Representative types of radiant drying systems are set forth inU.S. Pat. No. 5,958,275 to Joines et al.; U.S. Pat. No. 5,998,774 toJoines et al.; U.S. Pat. No. 6,075,232 to Joines et al.; U.S. Pat. No.6,087,642 to Joines et al.; U.S. Pat. No. 6,246,037 to Drozd et al. andU.S. Pat. No. 6,259,077 to Drozd et al.; all of which are incorporatedherein by reference. Such types of radiant drying systems can bemanufactured from materials such aluminum and aluminum alloys. See,also, U.S. Pat. No. 5,563,644 to Isganitis et al., which is incorporatedherein by reference.

For the evaporation of solvent, radiant-type drying systems arepreferred, because typical infrared-type drying systems requirerelatively long residence times to adequately remove effectivequantities of solvent or liquid carrier (e.g., water) from the paper web55. For fast moving paper webs 55 running at nominal cigarette makingmachine speeds, the application of sufficient heat demands the need forrelatively long infrared-type drying apparatus. Additionally, sufficientheat from infrared-type drying systems requires the use of relativelyhigh temperatures; thus providing the propensity for scorching andbrowning of certain areas of the paper web, and the risk of fire. Forexample, for a conventional cigarette making machine operating so as toproduce about 8,000 cigarette rods per minute, and having bands ofadditive material applied to the advancing paper web so that about 1 mgof water is applied to each individual cigarette rod, about 350 to about700 watts per hour is effectively required to remove that water from thepaper web.

A microwave-type drying system is desirable because effectively highamounts of heat can be employed in controlled manners. An exemplarysystem is one that employs planar wave guide of about 36 inches inlength, an internal width of about 1.6 inches, and an internal depth ofabout 3.7 inches. More preferred systems are those that employ planarwave guides of either about 54 inches, about 75 inches or about 96inches of total length. Preferred wave guides are of dimension to allowpassage of only lowest order (i.e., TE₁₀) or single mode radiation. Anexemplary system also can possess inlet and outlet ends 282, 283 thatboth have widths of about 1.75 inch and heights of about 0.37 inch.Within the inner region of the drying system, immediately within eachend of the inlet and outlet ends 282, 283, are positioned choke flanges,pin chokes (not shown) or other means to assist in the prevention ofescape or leakage of radiation from the system; and those flanges orpins typically extent about 3 inches into the system from eachrespective end.

Microwave-type drying systems can apply heat to desirable locations onthe paper web 55 where heat is needed (i.e., in the printed regions ofthe paper web). In one preferred radiant-type drying system, microwaveenergy is launched at one end of a waveguide and is reflected at theother end of that waveguide, resulting in the paper web experiencingradiant energy for effectively an extended period. Precise dryingcontrol can be achieved by attenuating the microwave energy and/or thepath of the paper web within the microwave drying system. Suchradiant-type drying systems thus can be used to evaporate the solvent orliquid carrier (e.g., water) of the additive material formulations byapplying the microwave energy uniformly throughout the patterned region(e.g., to the bands of applied additive material coating formulation).

The controls for the radiant-type dryer (e.g., the microwave control andassociated safety systems) most preferably are integrated into theprogrammable logic controller-based (PLC-based) control system (notshown) for supervisory control. The PLC-based system (not shown) enablesradiant energy production, and disables the radiant energy productionwhen radiant energy is not needed for drying (e.g., such as when theproduction system is stopped or paper web experiences a break). The topand bottom regions of the wave guide of the drying system in portions ofthe drying region can be perforated with a plurality of perforations(not shown) to allow for the removal of moisture, without allowingradiation (e.g., microwave radiation) from escaping into thesurroundings. A suitably designed shroud 287 and an electrically drivenfan (not shown) can be placed over the top of those perforations inorder to remove the evaporated moisture away from the paper web andremove dust from the system. If desired, the fan (not shown) also can beunder the control of the PLC-based system, and as such, only operateduring operation of the cigarette manufacturing system 8.

For a radiant heating system 280 for the embodiment shown in FIG. 2,radiant microwave energy is supplied by a generator 290 forelectromagnetic radiation, which is located one end of that system.Typically, higher power generators are used to produce heat to removegreater amounts of moisture; and generators producing up to about 10 kWof power, and usually up to about 6 kW of power, are suitable for mostapplications. Radiation produced by the generator is passed throughappropriate wave guides and circulators (not shown). The microwaveradiation passes through a curved wave guide 292 and through a dryingregion 294 for the paper web 55. A typical drying region for a microwavedrying system has a length of about 30 inches. As such, the radiationsupplied to the drying system and the paper web 55 move in the sameoverall direction through that drying system. Radiation that travelsthrough the drying region 294 is reflected by suitable reflector 296(i.e., a short plate or reflector plate) at the other end of the dryingsystem. That radiation is reflected back through the drying region, backthrough the channel at the other end of the heating system, and as such,the reflected radiation and the paper web 55 move in an overall countercurrent manner relative to one another. Any remaining radiation isappropriately redirected through appropriately positioned wave guidesand circulators to a dry air-cooled load 298, or other suitableradiation dissipation means. As such, the radiation is converted toheat, and the resulting heat can be removed using electrical fans (notshown) or other suitable means.

In a preferred embodiment (not shown), the positioning of the heatingdevice 280 shown in FIG. 2 is reversed (e.g., the heating device isrotated 180°) such that the paper web 55 enters at the end of theheating device possessing the reflector 296 and exits at the end throughwhich radiation enters the channel 292 from the generator 290. As such,radiation entering the drying system from the source of radiation andthe paper web 55 travel in an overall counter current manner relative toone another. It also is possible to position two or more of those typesof heating devices in series (not shown), so as to provide a manner forsubjecting the paper web 55 to prolonged exposure to radiation.

The paper web 55 having certain types of additive materials 73 appliedthereto is subjected to exposure to radiation capable of causingcomponents of the additive materials to undergo polymerization. Typicaltypes of radiation that are suitable for such a purpose includeultraviolet (uv) and electron beam radiation. That is, coatingformulations incorporating pre-polymer components can be exposed tosuitable radiation of a type and in a manner sufficient to cause thepre-polymer components to undergo polymerization reactions and hencesolidify. For the treatment of those types of coating formulationsapplied thereto, the heating/cooling control device 280 is replaced witha source of radiation, in order to provide for exposure of the coatingformulation on the paper web to radiation that causes solidification ofthe additive material. A suitably designed reflective shield, shroud orcover 287 can be positioned over that radiation source 280 in order toensure that radiation is directed toward the coating formulationpositioned on the paper web, and in order to minimize or preventemission of radiation to undesired locations within the environment nearthe cigarette making machine assembly 8.

The additive applicator 70 used in conjunction with the supply machine200 most preferably is driven by a servo drive control system (notshown) or other suitable control means. As such, the positioning of theadditive material on the paper web 55 can be controlled relative to thelocation that the continuous cigarette rod 170 that is manufacturedusing the second component 10 is cut into predetermined lengths, andhence, registration of the applied pattern of additive material on afinished cigarette can be achieved. That is, the automated cutting knife(not shown) for subdividing the continuous rod into predeterminedlengths can be controlled relative to those components used to applyadditive material to the paper web that is used to provide thatcontinuous rod.

The paper web 55 exits the temperature control device 280 and isadvanced to the cigarette making machine 10. Direction of the paper web55 is provided by suitably aligned series of idler rollers 312, 314, 316(or guideposts, turning bars, or other suitable means for directing thepaper web from the first component 200 to the second component 10).Suitable pathways for travel of the paper web 55 can be provided bysuitably designed tracks or tunnels (not shown). As such, there isprovided a way to direct the paper web from the first component 200 tothe second component 10.

The continuous paper web 55 is received from the first component 200 bythe second component 10. Typically, the paper web 55 is directed fromidler roller 316 to roller 60 of the cigarette making machine 10, orother suitable location. The paper web 55 travels through printingassembly 65 where indicia can be printed on the outer surface 90 of thatweb, if desired. The paper web 55 then travels to the garniture region45 of the cigarette making machine 10, where there are providedcomponents for manufacturing a continuous cigarette rod 170 by wrappingthe tobacco filler 20 in the paper web. The garniture conveyor belt 130advances that paper web through that garniture region. At the left endof the suction conveyor system 28, tobacco filler 20 is deposited fromits source on the foraminous belt 32 onto the paper web 55. Thegarniture region 45 includes finger rail assembly 140, garnitureentrance cone 144, scrape 155, tongue 160, folding mechanism 180 andadhesive applicator 184, that are employed to provide a continuouscigarette rod 170. The continuous rod 170 is subdivided into a pluralityof rods (not shown), each of the desired length, using known techniquesand equipment (not shown). Those rods then most preferably have filterelements attached thereto, using known techniques and equipment (notshown).

Referring to FIG. 3, there is shown a two-component automated cigarettemaking machine assembly 8 that is constructed by coupling a wrappingmaterial supply machine 390 (e.g., a first component) with a cigarettemaking machine 10 (e.g., a second component). The assembly 8incorporates those general components that operate in the overallgeneral manner that have been described previously with reference toFIG. 2.

The supply machine 390 most preferably is a free-standing machine thatis capable of providing a patterned web of wrapping material 55 to aconventional (or suitably modified) cigarette making machine 10. Thesupply machine 390 includes a frame 205 that supports at least oneunwind spindle assembly 220 onto which a first bobbin 224 is mounted.The paper web 55 is threaded through a tension sensor 236, which inconjunction with a braking component 239 connected to the shaft of theunwind spindle assembly, maintains a desired amount of tension on thepaper web 55 as it is transferred from the bobbin 224.

In operation, a continuous paper web 55 supplied from a bobbin 58 isrouted through a path defined by a series of idler rollers 245, 247 andguideposts 255, 256. Optionally, though not preferably, the paper web 55can be routed through a heating/cooling control unit (not shown) as thepaper web passes through the series of rollers and guide posts. Thepaper web then is routed through an additive applicator system 400. Theadditive material 73 most preferably also is applied to predeterminedlocations on the inside surface 88 of the paper web 55.

A representative additive applicator system 400 comprises at least onenon-contact application device 404. That is, for a non-contact device,the components used to apply additive material to the paper web do notcome into direct physical contact with the paper web. The design andarrangement of the non-contact application device 404 can vary. For theembodiment shown, the applicator system 400 comprises a series ofnon-contact applicators 404, 405, 406, 407; and in particular, aplurality of non-contact printheads. The additive material 73 typicallyis provided from a supply source reservoir (not shown) through tubing(e.g., Tygon-type tubing) or other suitable supply means (not shown) toa port or supply region infeed regions of those applicators. Eachadditive applicator of the applicator system 400 can be of a type thatapplies additive material 73 that has a finely divided solid powder form(e.g., an electrostatic deposition type of printing device) or that hasa fluid form (e.g., an ink jet type of printing device). Mostpreferably, the use of such types of techniques to apply coatingformulation to a substrate can be computer controlled.

Representative additive applicators can incorporate those various typesof technologies contained in the non-contact printing systems andassociated printing system components available from sources such asCanon Kabushiki Kaisha, Durst Phototechnik AG, Inca Digital Printers,Gradco (Japan) Ltd., Leggett & Platt Digital Technologies, MimakiEngineering Co. Ltd., Olec Corporation, Tampoprint AG, Vutek, Inc.,ZUND, Spectra Inc., Xaar, Xerox Corporation, Brother Kogyo KabushikiKaisha, Hitachi, Ltd., Toshiba Tec Corporation, Hewlett-Packard Company,Hitachi Koki Imaging Solutions, Inc. and Ink Jet Technology Inc.

Electrostatic deposition printing is a non-impact method of printingthat uses dry coating formulation, static electricity, and heat, tomaintain components of that coating formulation in contact with thesubstrate. That is, extremely small sized particles (e.g., sub-micronsize particles) incorporating polymeric material (e.g., meltable orthermoplastic materials) are applied to a substrate. Heat is provided tothe coated substrate, such as through appropriate exposure to radiationfrom quartz tube lamps (not shown) or by suitable contact with heatedrollers (not shown). As such, the plastic materials of the coatingformulation that are exposed to heat melt, and hence stick (e.g., fuseor otherwise become fixed) to substrate.

Representative types of electrostatic precipitation techniques andequipment components are set forth in U.S. Pat. No. 6,501,925 toYamamoto et al. and U.S. Pat. No. 6,519,421 to Inoue; and US PatentApplication 2002/0150829 to Zhao et al.; which are incorporated hereinby reference.

Ink jet printing is a non-impact method of printing that involvesejecting a coating formulation from a nozzle onto a substrate inresponse to an electronic digital signal. The actual coating formulationejection method can occur via several processes, and can involve the useof pressurized nozzles, electrostatic fields, piezoelectric elementswithin nozzles, and heaters for vapor phase bubble formation. Variousprinting methods are described in Output Hard Copy Devices, Durbeck andSherr (eds.), Chapter 13 (1988) and Handbook of Imaging Materials, 2ndEd. Diamond and Weiss (eds.) Chapter 14 (2002); which are incorporatedherein by reference.

Representative types of ink jet printing equipment components,methodologies and associated technologies are set forth in U.S. Pat. No.4,251,824 to Hara et al.; U.S. Pat. No. 4,410,899 to Haruta et al.; U.S.Pat. No. 4,412,224 to Sugitani; U.S. Pat. No. 4,463,359 to Ayata et al.;U.S. Pat. No. 4,532,530 to Hawkins; U.S. Pat. No. 4,601,777 to Hawkinset al.; U.S. Pat. No. 5,281,261 to Lin; U.S. Pat. No. 5,563,644 toIsganitis et al.; U.S. Pat. No. 5,764,257 to Miyazawa et al.; U.S. Pat.No. 6,181,439 to Bronstein et al.; and U.S. Pat. No. 6,298,780 toBen-Horin et al.; and US Patent Application 2003/0067527 to Temple; andEuropean Patent Specification 1,003,643; which are incorporated hereinby reference.

Typical printheads incorporate a plurality of ejectors or tiny nozzles.For example, a typical printhead can incorporate about 300 to about 600nozzles. Such printheads are capable of applying a series of tiny dotsof coating formulation at desired locations on a substrate, such as acontinuous paper web. Although the sizes of the individual dots canvary, typically such dots have diameters in the range of about 50 toabout 60 microns. The number of dots applied to a unit area of substrate(e.g., the resolution of the application) can vary, and a representativeapplication can be provided at about 1440 by about 720 dots per squareinch (dpi). For example, for a printing pattern having a resolution ofabout 600 dpi, a printed band having a width of about 24 mm and a lengthof about 4.2 mm possesses about 100 printed dots.

The number of printheads can vary. The number of printheads andassociated nozzles that are employed depends upon factors such as thewidth of the paper web, the speed at which the paper web moves, theoverall size of each desired pattern, the design and positioning of theprinted pattern relative on the paper web, the number of dots in eachpattern, the sizes and weights of the dots in each pattern, and thespeed at which coating formulation can be successively ejected from eachnozzle. There can be at least 1, at least 5, at least 10, at least 20,even at least 30 printheads. The upper limit of the number of printheadscan be determined by the size and operation of those printheads.

If desired, the various heads can be positioned and directed to depositfurther amounts of coating formulation on or over coating formulationthat previously has been applied to the paper web. That is, furtheramounts of coating formulation can be superimposed over previouslydeposited amounts of coating formulation. Such further amounts ofcoating formulation can be identical in composition to, or differentfrom, that of the coating formulation that previously has been appliedto the paper web. As such, layered patterns of the general types setforth in U.S. patent application Ser. No. 10/303,648, filed Nov. 25,2002, can be provided.

The various printheads and associated nozzles can be arranged in avariety of ways. An array of ejectors can be formed by butting togetherseveral printheads, forming a printhead frame or bar. The printheads canbe arranged on the frame so as to remain stationary on that frame, orthe printheads can be movable on a track. Such a frame can be designedso as to be movable, or the frame can be designed so as to remainstationary. Movable printheads can be designed so as to move in anumerous directions; for example, back and forth, perpendicular to,parallel to, or diagonally, relative to the longitudinal axis of thepaper web. The various printheads can be positioned side by side (e.g.,transversely relative to the path of the moving paper web), and thevarious printheads can be positioned in a length-wise fashion along therelevant portion of the supply machine 390 (e.g., longitudinallyrelative to the path of the moving paper web).

The manner by which the desired pattern is printed can vary. Forrecurring bands of about 10 mm width and 24.5 mm length on a 27 mm widestrip of continuous paper web, which bands are positioned transverselyto the longitudinal axis of the paper web, and which bands are spacedabout 20 to about 60 mm apart, various portions of each band can beproduced from the application resulting from a combination of a seriesof printed segments provided from the nozzles of the various printheads.

For a very rapidly moving paper web, portions of a printed pattern canbe provided by individual printheads and associated nozzles of a seriesof printheads that cooperate to provide the desired overall pattern. Anexample of a manner or method by which a series of printheads can beused to produce various portions of the pattern on a fast movingcontinuous paper web is as follows. A first series of printheads andnozzles can combine to provide a first portion of a band of a series ofspaced bands; a second series of printheads and nozzles combine toprovide a second portion of that band of that series of bands; a thirdseries of heads and nozzles combine to provide a third portion of a bandof that series of bands; and a fourth series of heads and nozzlescombine to provide a fourth portion of a band of that series of bands.That is, deposition of coating material as sub-patterns from individualheads and nozzles can be programmed to the speed of travel of thecontinuous paper web as well as to the relative sizes and spacings ofthe various bands.

An example of a manner or method by which a series of printheads andnozzles can be used to produce repeating series of patterns on a fastmoving continuous paper web is as follows. A first series of printheadsand nozzles can combine to provide a first band of a first series ofspaced bands; a second series of printheads and nozzles combine toprovide a second band of that first series of bands; a third series ofprintheads and nozzles combine to provide a third band of that firstseries of bands; and a fourth series of printheads and nozzles combineto provide a fourth band of that first series of bands. Then, the firstseries of printheads and nozzles can combine to provide a first band ofa second series of spaced bands; the second series of printheads andnozzles combine to provide a second band of that second series of bands;the third series of printheads and nozzles combine to provide a thirdband of that second series of bands; and the fourth series of heads andnozzles combine to provide a fourth band of that second series of bands.Controlled timing of the speed of the paper web and the application ofcoating formulation provided by each nozzle results in application ofcoating formulation at the desired locations on the paper web. As such,the printed pattern is continuously repeated in order to provide acontinuous paper web printed with a virtually endless pattern ofessentially identical bands equally spaced along the length of thatpaper web.

In order to ensure proper positioning of the coating formulation on thepaper web, it is desirable to ensure that the nozzles operate veryquickly to provide coating formulation (e.g., it is highly desirable forthe response times of those nozzles to be very short, and for thosenozzles to turn on and off very quickly). For a fast moving paper web(e.g., a paper web traveling at a speed of about 500 meters per minute),a non-contact applicator that operates relatively slowly can result inapplication of coating formulation that is streaked across that paperweb (i.e., undesirable streaking occurs when the positioning and speedof operation of the nozzles are relatively slow as compared to the speedof travel of the paper web).

After the additive material 73 has been applied to the paper web 55,components of the additive material is fixed to maintain components ofthat material to the paper web. Treatments such as exposure to radiationfor curing or heating/cooling steps are used to ensure that componentsof the additive material form a film on the desired regions of the paperweb. Prior to or after such types of treatments, the paper web 55 can beexposed to a sensor or detector 95 for a registration system and/or aninspection system (not shown). Preferably, the detector 95 is positionedso as to receive information concerning the paper web 55 immediatelyafter additive material 73 has been applied to that paper web.Typically, the detector 95 is used in conjunction with the certainregistration systems and inspection systems, and in conjunction withsuitable marker components that are incorporated as components of theadditive material 73. Representative types of sensors, detectors andinspection system components and description of inspection systemtechnologies and operation thereof have been set forth hereinbefore withreference to FIG. 1.

For additive materials 73 that have been electrostatically deposited onthe paper web 55, the paper web typically is heated and cooled. Thepaper web 55 can be passed through a heating/cooling control device 280,or other suitable means for controlling heat to which the paper web issubjected. The control device 280 can be used to alter the heat to whichthe paper web 55 and additive material is subjected (e.g., by raising orlowering the temperature). For example, the control device can be aheating device adapted to soften the additive material 73 that has beenapplied to the paper web 55, followed by a cooling device to harden thesoftened additive material. Alternatively, for example, theheating/cooling control device can be a cooling device adapted to assistin the hardening melted additive material 73 that has been applied tothe paper web 55 using a heated additive applicator system 400.Typically, the heating/cooling control device 280 has a tunnel-typeconfiguration through which the paper web 55 is passed (through an inletend 282 and out an outlet end 283); and during the time that the paperweb is present within that tunnel region, the paper web is subjected toheating supplied using infrared convection, a series of heated rollersor radiant heating devices; or cooling supplied using refrigerant-type,liquid carbon dioxide-type or liquid nitrogen-type cooling devices.

The size of the heating/cooling device 280 can vary, particularlybecause that device is positioned and supported by a component 200 thatis physically separated from, and spaced from, the cigarette makingmachine 10. That is, there is provided sufficient room to subject thepaper web 55 to treatment using the heating/cooling device 280.Exemplary heating/cooling devices 280 have lengths of about 2 feet toabout 10 feet, with lengths of about 3 feet to about 8 feet beingtypical, and about 4 feet to about 7 feet being desirable. The distancethat the paper web 55 travels through the heating/cooling device 280(i.e., the length of travel through that device) can vary. For example,the paper web 55 can be routed back and forth within the heating/coolingdevice 280 using a suitably adapted roller system configuration (notshown). The components of suitable and appropriate heating/coolingdevices will be readily apparent to those skilled in the art of thedesign, manufacture and use of electrostatic deposition printingdevices.

For additive materials 73 incorporating pre-polymer components that havebeen applied to the paper web 55, those pre-polymer components arecured. For example, for additive materials 73 that have been printedonto paper webs 55 using ink jet application devices, the paper webs aresubjected to exposure to suitable radiation. The paper web 55 can bepassed through a suitably modified heating/cooling control device 280 inorder that radiation curable components of the coating formulation 73 isexposed to a sufficient amount of the appropriate radiation so as tosolidify the pre-polymer components of that coating formulation.Exemplary types of radiation for curing radiation curable formulationsare set forth in U.S. Pat. No. 5,679,115 to Fritzsche et al. and USStat. Inv. Reg. H1517 to Erickson et al.; which is incorporated hereinby reference. Radiation curable systems do not necessarily requireheating or cooling of components of the coating formulation or the paperweb prior to application of the coating formulation to the paper web, orheating or cooling of the treated paper web after the additive materialshave been applied and fixed thereto.

One type of radiation is electron beam radiation. Such radiation is anionizing radiation, and as such, free radical polymerizable compositionswithin coating formulations can be solidified using electron beamradiation (i.e., gamma radiation). Representative types of electron beamradiation curing systems are set forth in US Patent Application2002/0135290 to Avnery, which is incorporated herein by reference.Electron beam curing can be carried out using the technologies that areemployed in the types of curing systems available as EZCure ElectronBeam Systems from Energy Sciences, Inc.

One type of radiation is ultraviolet (uv) radiation. Such radiation isionizing radiation, and as such, free radical polymerizable compositionswithin coating formulations, that also can incorporate suitable freeradical initiation systems or photoinitiators, can be solidified usinguv radiation. Sources of radiation are mercury lamps, xenon lamps, andthose types of sources set forth in US Patent Application 2003/0035037to Mills et al., which is incorporated herein by reference.

If desired, so-called hybrid types of curing systems can be employed.For example, relevant components of coating formulations can be curedusing both uv and electron beam forms of radiation.

The amount of ionizing radiation required to effectively cure therelevant components of the coating formulations can vary. Typically, theamount of radiation is in the range of about 5 to about 50 kGray. Theradiation is of an intensity, and the relevant components are exposed tothat radiation for a period of time, in order that the relevantcomponents of the coating formulation is exposed to a sufficient amountof radiant energy to provide for the desired degree of polymerization.The selection of appropriate sources of ionizing radiation can bedetermined by experimentation, and the identity and operation ofsuitable sources of ionizing radiation will be readily apparent to thoseskilled in the art of design, manufacture and use of devices for curingradiation curable compositions.

The paper web 55 exits the temperature control device 280 and isadvanced to the cigarette making machine 10. Direction of the paper web55 is provided by suitably aligned series of idler rollers 312, 314, 316(or guideposts, turning bars, or other suitable means for directing thepaper web from the first component 390 to the second component 10).Suitable pathways for travel of the paper web 55 can be provided bysuitably designed tracks or tunnels (not shown). As such, there isprovided a way to direct the paper web from the first component 390 tothe second component 10.

The continuous paper web 55 is received from the first component 390 bythe second component 10. Typically, the paper web 55 is directed fromidler roller 316 to roller 60 of the cigarette making machine 10, orother suitable location. The paper web 55 travels through printingassembly 65 where indicia can be printed on the outer surface 90 of thatweb, if desired. The paper web 55 then travels to the garniture region45 of the cigarette making machine 10, where there are providedcomponents for manufacturing a continuous cigarette rod 170 by wrappingthe tobacco filler 20 in the paper web. The garniture conveyor belt 130advances that paper web through that garniture region. The resultingcontinuous rod 170 is subdivided into a plurality of rods (not shown),each of the desired length, using known techniques and equipment (notshown). Those rods then most preferably have filter elements attachedthereto, using known techniques and equipment (not shown).

The cigarette making machine assemblies and configurations describedwith reference to FIGS. 2 and 3 are representative of cigarette makingmachine assemblies and configurations that can be used to providetobacco filler 20 to a garniture region 45 from one location, and thepatterned paper web 55 to the garniture region from another location.Furthermore, the representative cigarette making machine assembly (i.e.,with the component that provides the patterned paper web positioned tothe front and to the right of the component that incorporates thetobacco source and the garniture assembly) is such that the generaldirection of travel of the paper web through the wrapping materialsupply machine is essentially parallel to the direction of travel of thepaper web through the garniture region of the cigarette making machine.However, the positioning of the wrapping material supply machine to thecigarette making machine can vary. For example, the wrapping materialsupply machines 200, 390 can be positioned beside or behind thecigarette making machine 10; or positioned generally perpendicular tothe garniture region of the cigarette making machine 10. In suchcircumstances, the path of travel of the paper web from the wrappingmaterial supply machine to the cigarette making machine can beaccomplished through the use of appropriately positioned idler bars androller guides. The exact path of travel of the paper web is a matter ofdesign choice, and the selection thereof will be readily apparent tothose skilled in the art of design and operation of cigarettemanufacturing equipment.

Referring to FIG. 4, there is shown a three-component automatedcigarette making machine assembly 8 that is constructed by coupling awrapping material supply machine 390 possessing a non-contact printingelectrostatic deposition or ink jet printing component (e.g., a firstcomponent) with a cigarette making machine 10 (e.g., a secondcomponent). A roll application machine 450 (e.g., a third component) ispositioned between the first and second components. The assembly 8incorporates those general components that operate in the overallgeneral manner that have been described previously with reference toFIGS. 2 and 3. That is, the assembly 8 includes a cigarette makingmachine 10 that is described generally with reference to FIGS. 2 and 3,and a wrapping material supply machine 390 that is described generallywith reference to FIG. 3. The roll application machine component 450 ofthe assembly 8 provides a system 460 for applying a coating formulation462 to the paper web 55 that has had additive material 73 appliedthereto using supply machine 390.

A continuous paper web 55 is provided from a bobbin 224 from the unwindspindle assembly 220 of the supply machine 390. That paper web 55 isrouted through a path defined by idler rollers 245, 247 and guideposts255, 256. The supply machine is adapted to incorporate an additiveapplication apparatus 70 in order that a coating formulation of additivematerial 73 can be applied at desired locations to the inner surface 88of the paper web 55. A series of non-contact applicators 404, 405, 406,407 apply additive material 73 to the paper web. A detection device 409is used to locate and record the location of the additive material 73that has been applied to the paper web. The paper web 55 and additivematerial 73 that has been applied thereto then is passed through aheating/cooling or source of radiation device 280 in order to providetreatment sufficient to fix the additive material to the paper web.

The paper web 55 is routed through a series of guide posts and rollers470, 471, 472, 473, 474 in order to be appropriately routed through thethird component 450 of the cigarette making machine assembly 8. Thethird component 450 possesses a frame 205 and a roll application unit460 for applying a second coating formulation 462 to the paper web 55. Arepresentative roll application unit 460 possesses pick-up roller 78 andapplicator roller 82. A detection device 409 is used to locate andrecord the location of the second additive material 462, and optionallyalso the first additive material 73, that has been applied to the paperweb. The paper web 55 having two types of additive material appliedthereto then is routed through a heating/cooling device 280, such as isdescribed previously with reference to FIG. 2. The paper web 55 thenexits the heating/cooling device 464 at outlet end 465 and travels on tothe second component 10 of the three component arrangement 8.

Tobacco filler 20 and components for manufacturing a continuouscigarette rod 170 from the tobacco filler is carried out using thesecond component of that system 10. The paper web 55 is routed from thethird unit 450 to the second unit 10 using a series of rollers and guidebars 312, 314, 316 and 60 to the garniture region 45 of the secondcomponent 10. The garniture conveyor belt 130 is used to transport thatpaper web through the garniture region 45 of the cigarette makingmachine 10. The paper web 55 also can travel through printing assembly65 where indicia can be printed on the outer surface 90 of that web, ifdesired.

For preferred three component systems, the three components areindependent, stand alone units. The third component 450 of the system ispositioned between the first component 390 and second component 10, andis used to apply coating formulation to the paper web that is suppliedby the first component. The third component of the system also isadapted so that the continuous paper web passes from that thirdcomponent to the second component of the system for cigarettemanufacture. As such, coating formulation from a second applicationsystem can be applied to a paper web over the coating formulationpreviously applied to that paper web by a first application system. Forexample, a coating formulation that is virtually absent of solvent canbe applied to the paper web, and the pre-polymer components of thatformulation can be cured to provide a first coating layer; and then, awater-based starch containing coating formulation can be applied as asecond layer over the first layer. As such, superimposed layers ofcoating material can be applied to a paper web, such as is set forth inU.S. patent application Ser. No. 10/303,648, filed Nov. 25, 2002.

For the cigarette making machine assemblies described with reference toFIGS. 1 through 4, registration of the transversely positioned bands ofadditive material on a continuous paper web so as to be within atolerance window is a very desirable feature when those bands are usedfor the production of cigarettes that meet certain standards withregards to low ignition propensity criteria. Registration of thepatterns (e.g., bands) applied to continuous paper webs within atolerance window can be carried out whether the patterns are appliedoff-line (e.g., as pre-printed patterns) or on-line (e.g., as patternsapplied on the cigarette making apparatus). In particular, a 2-axescontrol system (i.e., a system that controls two independent motors) isused within the cigarette making apparatus in conjunction with a highspeed band sensor (i.e., which is fast enough to respond to nominalcigarette making speeds). A first servo motor drives the flying knife ofthe cigarette making machine. The knife position at rod cut off locationis derived by an encoder mechanically coupled to the cut off knife, andthis signal is used as a reference point for determining the position ofthe band. A second servo motor drives the garniture belt and theforaminous conveyor belt, and a second encoder provides the feedbackregarding cigarette making speed. The detector senses a band and thelocation of that band with respect to the cutoff knife. If the bands areout of registration on the cigarette rods, the servo control systemtypically slows down the garniture belt relative to the cut off knife sothat the knife temporally will cut shorter rods until the continuoustobacco rod is in registration. This can be achieved either by speedingup the cut off knife or slowing down the garniture belt. For example,the system can be programmed to make a small adjustment per rod (e.g.,such as 1 mm per cut change per rod) so as to walk the system into toregistration as smoothly as possible. However, for smaller adjustments,longer periods are required to bring the cigarette rods back within thetolerance window, and hence more short cigarettes will be rejected. Sucha registration system is particularly useful for making adjustments (i)during cigarette making machine start up; (ii) during machine operationafter recovery from a shutdown or after a new bobbin of paper web isspliced into the machine; (iii) during normal cigarette making machineoperation due to factors such as stretching of the paper web.

Referring to FIG. 5, there is shown a portion of a cigarette makingmachine assembly 8 that includes an additive applicator apparatus 70that uses rollers 78, 82 to apply additive material (not shown) directlyto the surface of a continuous strip of paper web 55. Such an additiveapplicator 70 is particularly useful for applying to a paper web 55additive materials that are liquid or liquid dispersions that are notparticularly viscous (e.g., formulations of additive materials havingviscosities of less than about 1,000 centipoise).

Additive applicator 70 is an assembly that includes a pick-up roller 78and a transfer roller 82 mounted adjacent to each other and through afirst or front roller support plate 1400 on the exterior front face ofthe cigarette making machine assembly 8. A second or rear roller supportplate 1408, located in the plane of and adjacent to the front rollerplate 1400, provides a surface to which other structures of the additiveapplicator 70 are mounted. Components of the additive applicatorapparatus 70, including rollers 78, 82 and support plates 1400, 1408 aremanufactured from materials such as stainless steel or hardened carbonsteel. Several rotatable guide rollers 1420, 1422, 1424, 1426, 1428 aresuitably fixedly mounted; such as to either the front roller plate 1408or rear roller plate 1410, depending upon the desired location of thoseguide rollers. Those guide rollers provide the path over which the paperweb 55 travels from a bobbin (not shown), past the additive applicator70, and on to other downstream destinations of the cigarette makingmachine assembly.

The additive applicator 70 also includes a manifold 1444 positionedabove an additive material reservoir 1448, which is defined by thepositioning of a reservoir front arm 1452 and a reservoir rear arm 1454.Those arms 1452, 1454 are positioned above the pick-up roller 78. Tubing1458, or other suitable supply means, is connected to the manifold 1444and originates at a source of additive material (not shown) to providean input of additive material to reservoir 1448, and hence to the rollface of the pick-up roller 78. That portion of the additive applicatorassembly thus provides a sealed path for flow of additive material tothe region where that additive material is deposited onto the pick-uproller. Preferably, the reservoir front arm 1452 and rear arm 1454 eachinclude at least one port (not shown), located on the bottom sides ofeach of those arms 1452, 1454. At least one of those ports is an outputport through which additive material is supplied to the roll face of thepick-up roller 78. At least one other port is an input port throughwhich a suction pump (not shown) suctions excess additive material fromthe edges of the pick-up roller 78, and pumps excess additive materialback into the reservoir 1448 defined by arms 1452, 1454. The assemblyalso includes a collection pot 1465 positioned adjacent to and slightlybelow the pick-up roller 78. The collection pot 1465 serves as atemporary collection location for excess additive material removed fromthe pick-up roller 78.

The manifold 1444 is attached to a glue manifold pivot plate 1470, whichis attached to the front roller plate 1400 and the rear roller plate1408. Such attachment leaves the manifold 1444 with the capability ofmoving upward and downward about a manifold pivot pin (not shown).Movement of the manifold 1444 upward from the operative position allowsaccess to those regions located below the manifold. Access to thatregion is desirable have access to the reservoir arms 1452, 1454, toinsert, remove and service the pick-up roller 78, and for maintenanceand service of the collection pot 1465. In addition, the reservoir arms1452, 1454, are movable upward and downward about a reservoir pivotshaft (not shown) to allow access to the pick-up roller 78 and thecollection pot 1465.

The transfer roller 82 and the pick-up roller 78 are positioned intooperative engagement with one another using a roller pressure plate1480. The roller pressure plate 1480 is operably connected to an aircylinder 1484, or other suitable means for applying force to rollers 78,82. The air cylinder 1484 utilizes compressed air to force the rollerpressure plate 1480 about a pressure plate pivot shaft 1488 into and outof engagement with the transfer roller 82. Movement of the rollerpressure plate 1480 to engage and disengage the pick-up roller 78 withthe transfer roller 82 can programmed, and as such a microprocessorassociated with the operation of the cigarette making machine can beused to control movement of that plate 1480.

The additive applicator 70 further comprises a roller lift bracket 495mounted to the front roller plate 1400, and that lift bracket ismovable. The roller lift bracket 1495 includes a pair of rollers 1500,1505, or other suitable means for controlling the path of travel of thepaper web 55. The roller lift bracket 1495 is operably connected to anair cylinder 1510, or other suitable means for applying force to thelift bracket. The air cylinder 1510 also is connected to a supply ofpressurized air by an air tube 1512, or other suitable connection andsupply means. The air cylinder 1510 utilizes compressed air to move thepair of rollers 1500, 1505 on the roller lift bracket 1495 into and outof rotating contact with the advancing paper web 55. For example, whenthe rollers 1500, 1505 on the roller lift bracket 1495 move downwardinto contact with the paper web 55, that paper web is likewise movedinto rotating contact with roll face of the transfer roller 82. As aresult of the contact of the paper web 55 with the transfer roller 82,the additive material applied to the transfer roller is transferred tothe inside surface of the paper web, in a desired pattern or fashion.Movement of the roller lift bracket 1494 and rollers 1500, 1505 into andout of contact with the paper web 55 can programmed, and as such amicroprocessor associated with the operation of the cigarette makingmachine can be used to control movement of that bracket 1494. The rollerlift bracket 1494 can be controlled by a signal received from thecigarette making machine, in order that the bracket can be retracted andthe paper web 55 can be moved so as to not be in contact with thevarious rollers when the cigarette making machine is not in normaloperation; and as such, problems associated with sticking of the paperweb to various components of the applicator apparatus 70 are minimized,avoided or prevented.

In operation, during the process of cigarette manufacture, the pick-uproller 78 is rotated counter-clockwise, and the transfer roller 82 isrotated clock-wise. Those rollers are engaged in contact by pressuresupplied by the pressure plate 1480. Additive material is feed from asource (not shown) to the manifold 1444, and from the manifold to thereservoir 1448, from the reservoir to the roll face of the pick-uproller 78, and onto the transfer roller 82. The additive material thenis transferred from the transfer roller to the paper web 55 as the paperweb advances across the surface of the rotating transfer roller 82. Thatis, as the paper web 55 advances across the surface of the rotatingtransfer roller 82, the roller lift bracket 1495 is moved downward, andthe rollers 1500, 1505 attached to that roller lift bracket are movedinto contact with the advancing paper web 55. As a result, the additivematerial on the surface of the transfer roller 82 is transferred to theinside surface of the advancing paper web 55 at locations correspondingto the pattern on the roller face of the transfer roller 82. The paperweb 55 having additive material applied thereto then is advanced todownstream locations of the cigarette making machine.

Referring to FIG. 6, there is shown a portion of a representativeadditive applicator apparatus 70. The pick-up roller 78 and the transferroller 82 are shown roll contact with one another and in operativeengagement. Pick-up roller 78 possesses a roll face having a pattern ofrecessed grooves 1535, 1537, 1539, 1541, 1543, having the form of spacedbands, or other desired pattern. Those recessed grooves provide alocation for a predetermined amount of additive material to bedeposited, and the size and shape of those grooves is a matter of designchoice. The pick-up roller 78 is rotated using a pick-up drive shaft1550 (shown as cut away); and the transfer roller 82 is rotated using anapplicator drive shaft 1554 (shown as extending from opening 1556 in theapplicator drive shaft box 1558. The drive shafts 1550, 1554 extendthrough an opening 1560 in the front roller support plate 1400, which isadjacent the rear roller support plate 1408. The pick-up roller 78 andthe transfer roller 82 are adapted to extend beyond the front faces ofeach of the front and rear roller plates 1400, 1408.

The applicator drive shaft box 1558 is adapted to be positioned andsecured to the back side of the front and rear roller plates 1400, 1408.A pick-up roller gear 1580 is in operative connection with the pick-updrive shaft 1550. A transfer roller gear 1584 is in operative connectionwith the applicator drive shaft 1554. Both gears 1580, 1584 are locatedexternal to the applicator drive shaft box 1558, and are positioned onthe back side of that drive shaft box 1558. Those gears 1580, 1584 haveinterlocking teeth such that rotation of one of those gears in onedirection causes rotation of the other gear in the opposite direction.The transfer roller gear 1584 is connected to a transfer roller pulley1590. A belt 1595 extends about the transfer roller pulley 1590 andaround a power source pulley (not shown). As a result, power forrotational movement is provided to the transfer roller shaft 1550 andtransfer roller 82 by rotation of the pulley 1590 by movement of thebelt 1595; and power for controlled rotational movement is provided tothe pick-up roller 78 by way of the drive shaft 1550 that is rotated byoperation of gears 1580, 1584. In addition, belt 1595 can act as atiming belt, and by suitable use of that belt to control the speed ofthe applicator drive shaft 1554 relative to the speed of operation ofthe cigarette making machine, it is possible to provide integral timingwith the cigarette rod subdivision mechanism (not shown) of thecigarette making machine. Thus, appropriate use of belt 1595 to connectappropriate gear mechanisms yields a method for providing pattern (e.g.,band) registration for each individual finished cigarette rods (notshown) that are cut from the continuous rod (not shown).

The applicator assembly 70 can further include a photoelectric sensorswitch (not shown) located above a point of roller engagement betweenthe pick-up roller 78 and the transfer roller 82. An exemplary sensor isa WT 12-2P430 from Sick, Inc. Output from the photoelectric proximityswitch is sent to a PLC or other suitable processor (not shown)associated with that photoelectric sensor (not shown) and monitors theamount (e.g., level) of additive material (not shown) in the regionabove that point of roller engagement of rollers 78, 82. Thus, as a flowof additive material is supplied from the manifold (not shown) andreservoir (not shown), an amount of the additive material forms at thepoint of engagement between those rollers 78, 82. When the amount ofthat additive material supplied to that region drops below apredetermined level for sufficient desired transfer of the additivematerial to the transfer roller 82, the information sensed and suppliedby photoelectric sensor controls a switch to activate a pump (notshown), and hence to supply more additive material to the reservoir.Similarly, deactivation of the pump can be controlled when a desiredlevel of additive material is achieved.

The applicator assembly 70 can further include sensors (not shown) thatassist in ensuring that proper amounts of additive material istransferred to the paper web. For example, an induction-type sensor (notshown) located in the region of a pick-up roller 78 can sense that thepick-up roller, and other associated components of the applicatorassembly, are in proper position. In addition, the cigarette makingmachine can be programmed such that when the induction sensor detectsthat the pick-up roller is not in proper position, that machine canprovide appropriate signal to the operator or cease operation. Inaddition, a further sensor (not shown) can be mounted on the rear rollerplate 1408 at a location of the paper web after that paper web haspassed over the transfer roller 82. That further sensor can be used todetect the presence, or degree of presence, of additive material on thepaper web 55. Detection of a sufficient presence of additive material onthe paper web 55 indicates that additive material transfer mechanismsare operating properly. The cigarette making machine can be programmedto alert the machine operator or stop movement of the paper web 55 ifthe further sensor detects an insufficient presence of the additivematerial on the paper web 55.

Referring to FIG. 7, there is shown a portion of a cigarette makingmachine assembly 8; and there also are shown relevant components ofanother representative additive applicator apparatus 70. Such anapplicator 70 is particularly useful for applying to a paper web 55 moreviscous additive materials, than those embodiments described previouslywith reference to FIGS. 5 and 6. More viscous additive materials usefulin applications involving cigarette paper include, for example,formulations of additive materials having viscosities of greater than100,000 centipoise. Such higher viscosity additive materials can becharacterized as pastes.

Additive applicator 70 is an assembly that includes a majorpick-up/transfer roller 1720 and a transfer pressure roller 1725 (orback-up roller) mounted adjacent to each other and through a frontroller plate 1730 secured to front exterior of a cigarette makingmachine. Each of a plurality of rollers 1422, 1426, 1428 is fixedlymounted to the front roller plate 1730; and those rollers provide guidesfor a path over which the paper web 55 travels from a bobbin (not shown)to the additive applicator 70 and on to other regions of the cigarettemaking machine 8.

Positioned adjacent to the major roller 1720 is a reservoir 1740 for theadditive material. The reservoir is maintained in place and secured tothe front roller plate 1730 by bolts (not shown) or other suitableconnection means. The reservoir 1740 is connected to a source (notshown) of additive material (e.g., a formulation having the form of apaste), through port 1742 near the top region of the reservoir 1740. Assuch, a source of additive material for the major roller 1720 isprovided. Typically, the additive material is supplied through tubing(not shown), such as Tygon-type tubing, that feeds the reservoir 1740through port 1742. The additive applicator 70 provides a sealed path forflow of the additive material to the point of deposit onto the majorroller 1720. The reservoir 1740 includes at least two ports (not shown)on the side thereof adjacent to the major roller 1720. One port is anoutput port positioned near the middle of the reservoir 1740, throughwhich additive material is supplied to the major roller 1720. At leastone other port is an input port through which excess additive materialis scraped from the edges of the major roller 1720, and is fed back intothe reservoir 1740.

The reservoir 1740 is attached to an assembly that is designed to exertpressure upon that reservoir. Such a pressure exerting assembly includesa reservoir pad 1748 that is positioned adjacent to the reservoir 1740.The reservoir pad 1748 is held in position by a reservoir pad retainer1753, which encompasses the reservoir pad 1748. Compression springs1756, 1758 are positioned between the reservoir pad retainer 1753 and areservoir spring retainer 1761, and provide resistance for tightening ofthe reservoir spring retainer 1761 toward the reservoir 1740. Screws1765, 1767, or other suitable connection means, are positioned througheach side of the reservoir spring retainer 1761, through the center ofeach respective compression spring 1756, 1758, and through a passage ineach side of the reservoir pad retainer 1753. The screws 1765, 1767 aremovable in and out of respective passages 1770, 1772 of the reservoirpad retainer 1753. The threaded ends of the screws 1765, 1767 arepositioned in threaded contact with threaded walls of the passages 1770,1772 of the reservoir pad 1748 so as to supply the application ofpressure to the reservoir pad 1748 when pressure is exerted against thereservoir spring retainer 1761.

An adjustment screw mounting plate 1778 is attached to the front rollerplate 1730 adjacent to the reservoir spring retainer 1761. An adjustmentscrew 1781 is threaded through the adjustment screw mounting plate 1778into contact with the reservoir spring retainer 1761. When theadjustment screw 1781 is adjusted a predetermined amount inward intoincreasingly compressive contact with reservoir spring retainer 1761,pressure is applied by the screws 1765, 1767 to the reservoir pad 1748.As a result, a predetermined amount of pressure is exerted on the pastereservoir 1740. The additive material formulation is caused to flow tothe reservoir 1740 by application of head pressure supplied from anupstream pumping system (not shown) or other suitable means. Theadditive applicator 70 also can be equipped with sensors and controldevices (not shown) of the type described previously with reference toFIG. 6.

A scraper plate 1783 is connected to the reservoir 1740. A compressionspring 1785 is positioned between a scraper 1783 and the scraper plate1787 such that the scraper is urged into operative contact with the rollface of the major roller 1720. As such, excess additive material on thesurface of the roll face of the major roller 1720 is scraped from thatroll face as the moving major roller passes the scraper, and thatmaterial is deposited back into the reservoir 1740. Thus, additivematerial carried by the major roller 1720 for transfer to the paper webis located in the desired location; within the pockets located on theroll face of that roller.

Rollers 1790, 1792, 1794 together with transfer pressure roller 1725 arepositioned on a roller lift bracket 1798. The roller lift bracket 1798is designed to be moved downward by the forces applied by air cylinder1805 about a lift bracket pivot plate 1806. The air cylinder 1805 isconnected to a source of pressurized air (not shown), and is employed toprovide for movement of the roller lift bracket 1798. The roller liftbracket 1798 is attached on one end to the front roller plate 1730 aboutlift bracket pivot plate 1806 through roller lift bracket pivot pin1807, and the lift bracket 1798 is movable. The roller lift bracket 1798further includes a lift bracket pivot sleeve 1808, which is slidinglyattached on the end opposite the pivot pin 1807 to lift bracket pivotplate 1806.

In operation, the transfer pressure roller 1725 and rollers 1790, 1792,1794 can be moved about the pivot pin 1807 so as to be positioned intoand out of contact with the upper surface of the paper web 55. When thetransfer pressure roller 1725 is moved into operative contact with themajor roller 1720, the transfer pressure roller 1725 rotates under thepower of the major roller 1720, but in the opposite direction to that ofthe major roller. Preferably, the major roller 1720 rotates clockwise,and the transfer pressure roller 1725 rotates counter-clockwise. Thetransfer pressure roller 1725 thus preferably contacts the advancingpaper web 55 at a point of engagement of the roll faces of the transferpressure roller 1725 and the major roller 1720. As a result of thepressured contact experienced by the paper web 55 as it travels betweentransfer pressure roller 1725 and the major roller 1720, additivematerial is applied to the paper web 55 in a predetermined pattern.Movement of the roller lift bracket 1798, transfer pressure roller 1725,and rollers 1790, 1792, 1794 into and out of contact with the paper web55 can programmed, and as such a microprocessor associated with theoperation of the cigarette making machine can be used to controlmovement of that lift bracket 1798. The roller lift bracket 1798 can becontrolled by a signal received from the cigarette making machine, inorder that the bracket can be retracted and the paper web 55 can bemoved so as to not be in contact with the various rollers when thecigarette making machine is not in normal operation; and as such,problems associated with sticking of the paper web to various componentsof the applicator apparatus 70 are minimized, avoided or prevented.

Referring to FIG. 8, there are shown relevant components of a portion ofa representative additive applicator apparatus 70. The major roller 1720possesses a roll face having a pattern of recessed grooves or pockets1820, 1822; thus providing a pocketed wheel. The diameter of the majorroller can vary, but suitable major roller has a diameter of about 104mm. Exemplary grooves provide spaced bands located so as to extendperpendicularly to the longitudinal axis of a paper web and across aportion of the width of that paper web, and are generally box-like inshape. The dimensions of the grooves can vary, and are dependent uponfactors such as the pattern of application that is desired; but suitablegrooves have depths of about 2 mils, longitudinally extending lengths ofabout 5 mm, and transversely extending lengths of about 23 mm. Thosegrooves 1820, 1822 are designed to contain additive material (not shown)and to transfer that additive material to a paper web (not shown) thatcontacts that roller face as the paper web travels past the roll face ofthe major roller 1720. As such, for the pattern shown, spaced apartbands are applied at predetermined intervals transversely to thelongitudinal axis of the continuous paper web. That is, the recessedgrooves 1820, 1822 provide a location for a predetermined amount ofadditive material to be deposited on a paper web; and the size and shapeof those grooves is a matter of design choice. The major roller 1720 ismanufactured from materials such as stainless steel, hardened carbonsteel, or the like.

The roller lift bracket 1798 supports rollers 1790, 1792, 1794 andback-up roller 1725. Back-up roller 1725, or “soft-faced” roller,typically is manufactured from stainless steel or hardened carbon steel,and the roll surface is provided by an overlying band or ring of asuitable material such as a rubber-type or elastomeric material.Suitable “soft-faced” rollers 1725 are adapted from those types ofcommonly used for component parts of conventional cigarette makingmachines, and are manufactured from materials commonly used inconventional cigarette making machines. The rubber-type material can bemanufactured from a suitable polyurethane material. The roller liftbracket also supports the air cylinder 1805 and the pivot plate 1806.The diameter of the back-up roller 1798 can vary, but a suitable back-uproller has a diameter of about 40 mm.

The reservoir 1740 for the additive material is assembled along with thereservoir spring retainer 1761, the adjustment screw mounting plate1778, the adjustment screw 1781, scraper 1783 and the scraper plate1787.

Positioned on the front roller plate 1730 are a plurality of rollers1422, 1426, 1428 and an opening 1824. The major roller 1720 is connectedto a roller drive shaft 1828 that passes through opening 1824 and to anapplicator drive shaft box 1830 that is in turn connected to a rollergear 1834. A belt 1595 extends about the roller gear 1834 and around apulley 1838 mounted to a power drive assembly 1841. Rotational power isprovided from the power drive assembly 1841 to the roller gear 1834 tothe roller shaft 1828 and to the major roller 1720. Timing belt pulley1842 can be used to receive input regarding the speed of operation ofthe cigarette making machine, and hence can be use in conjunction with abelt (not shown) to time operation of the other components of theapplicator apparatus 70.

Referring to FIG. 9, there are shown relevant components of a portion ofyet another representative additive applicator apparatus 70. Othercomponents of the additive applicator apparatus, and the generaloperation thereof, are described previously with reference to FIGS. 7and 8. Such an applicator 70 is particularly useful for applying to apaper web 55 more viscous additive materials. More viscous additivematerials useful in applications involving cigarette paper include, forexample, paste-type formulations of additive materials havingviscosities of greater than 100,000 centipoise.

Additive applicator 70 is an assembly including a major pick-up/transferroller 1850 that is generally similar to that pocketed roller describedpreviously with reference to FIGS. 5 and 6. For example, the diameter ofthe major roller 1850 can be about 104 mm, and the major roller can bemanufactured from materials such as stainless steel, hardened carbonsteel, and the like. Several rollers (not shown) are fixedly mounted tothe front roller plate 1730; and those rollers provide guides for a pathover which the paper web 55 travels from a bobbin (not shown) to theadditive applicator 70, between the roll faces of major roller 1850 andback-up roller 1725, and on to other regions of the cigarette makingmachine 8.

Positioned adjacent to the major roller 1850 is a reservoir 1855 for theadditive material. The reservoir is maintained in place and secured tothe front roller plate 1730 by bolts (not shown) or other suitableconnection means. The reservoir 1855 is connected to a source (notshown) of additive material (e.g., a formulation having the form of apaste), through the top region of the reservoir 1855. As such, a sourceof additive material for the major roller 1850 is provided. A portion ofthe reservoir 1855 is shown in phantom in order to show more clearly thepositioning of a portion of the major roller 1850 within the reservoir,and to more clearly show the positioning of the scrapers 1860, 1864against the roll face and side, respectively, of the major roller.Typically, the additive material is supplied through tubing (not shown),such as Tygon-type tubing, that feeds the reservoir 1850 through a port(not shown). The additive applicator 70 provides a path for flow of theadditive material to the point of deposit onto the major roller 1850.

A scraper 860 is connected to the body of the reservoir 1855. Thescraper 1860 is urged into operative contact with the roll face of themajor roller 1850. As such, excess additive material on the surface ofthe roll face of the major roller 1850 is scraped from that roll face asthe moving major roller passes the scraper, and that material isdeposited back into the reservoir 1855. Thus, additive material carriedby the major roller 1850 for transfer to the paper web is located in thedesired location; within the pockets located on the roll face of thatroller. Against the front side face of major roller 1850 is positioned ascraper 1864. A corresponding scraper (not shown) is positioned againstthe back side face of the major roller 1850. As such, the roll face andboth side faces are subjected to surface treatment by three scraperpieces arranged in a “U”-like configuration, so as to remove undesirableexcess additive formulation from those surfaces, and hence, maintainthose surfaces relatively clean by maintaining those surfaces relativelyfree of build up of coating formulation.

Referring to FIG. 10, there is shown certain relevant components anadditive applicator apparatus 70 representative of one aspect of thepresent invention. Such an application system 70 is useful for applyingadditive material (not shown) to a moving substrate, such as acontinuously moving strip of paper web (not shown). The applicationsystem 70 can replace those types of applicators described previouslywith reference to FIGS. 5 through 9. That is, the applicator system canbe positioned in those locations for applicator systems for thosecigarette making machines described previously with reference to FIGS.1, 2 and 4.

The applicator system 70 includes an outer housing 2100 that has anouter roll face 2110. A representative outer housing 2100 has agenerally circular shape, and the circumference of the roll face 2110 isabout 40.2 cm. The roll face or application face possesses a severalpassageways 2115, 2120, 2124, 2126, and those passageways extend fromthe outer surface of the outer housing to within a central cavity orinner region 2135 of that outer housing 2100. The shapes, dimensions,format and locations of the passageways can vary; but as shown,exemplary passageways each are composed of a series of holes (e.g., eachpassageway is composed of two rows each of about 23 mm across, and eachrow is composed of seven holes each of about 0.75 mm in diameter).Alternatively, for example, the passageways each can have the form ofone continuous passageway (e.g., each passageway has the form of a slothaving a width of about 23 mm and a length of about 0.25 mm). The sixrepresentative passageways are positioned so as to provide for spacedband shaped patterns on a continuous strip of paper web. Exemplarypassageways are positioned such that first and second passageways areseparated by about 30 mm, second and third passageways are separated byabout 104 mm, third and fourth passageways are separated by about 30 mm,fourth and fifth passageways are separated by about 104 mm, fifth andsixth passageways are separated by about 30 mm, and sixth and firstpassageways are separated by about 104 mm. As such, each revolution ofthe roll face can provide printing on a continuous paper web so as toprovide wrapping material for a six cigarette rods, each rod 67 mm inlength and each rod having one band printed at about 15 mm from one endthereof. The passageways can be provided by forming or machining thedesired passageway configuration through the desired locations of theouter housing; or the passageways can be formed or machined into areplaceable inserts 2150, that is designed to fit into a correspondingreceptacle 2153 in the outer surface region of the outer housing. Thenumber and positioning of the passageways can vary, depending uponfactors such as desired location of application on the wrappingmaterial, the size of cigarette rods manufactured using the wrappingmaterial, and the circumference of the roll face of the outer housing.Furthermore, the exact size, shape and format of the individualpassageways can vary, is dependent upon the desired configuration ofpattern to be applied to the wrapping material, and is a matter ofdesign choice.

The outer housing possesses an inner gear face 2160. The inner face hasa generally circular face, and possesses a series of gear teeth 2165,2167. For the exemplary applicator system shown, the inner facepossesses a series of 54 teeth, those teeth being characterized as DINModule 2. Gear teeth 2180, 2182 adjacent to one another in the regionsof the respective passageways are designed so as to extend essentiallyacross the width of the inner cavity; and the front and back regions ofthe other gear teeth 2165, 2167 are designed so that those teeth do notextend entirely across the width of the inner cavity. Typically, gearteeth having the shape of gear teeth 2165, 2167 are milled on the frontand back regions thereof, and the shape of gear teeth milled in such amanner is such that churning or other unnecessary movement of fluidcoating formulation within the inner region of the outer housing isminimized during operation of the applicator system. The outer housing2100 also possesses a front plate or face (not shown), to enclose innerregion of that outer housing. Typically, the passageways are positionedso as to extend from the outer surface of the outer housing to a troughregion between two adjacent gears 2180, 2182 of the inner surface ofthat outer housing. Thus, when the gears mate as shown, that matingoccurs near the uppermost region of the applicator system. As such,coating formulation (not shown) can be forced from the trough regionbetween those gears outwards to the outer surface of the outer housing.

Within the outer housing 2100 is positioned an inner gear 2200. Theinner gear is generally circular in shape, and possesses a series ofgear teeth 2210, 2212. For the exemplary application system shown, theinner gear 2200 possesses a series of 44 teeth, those teeth beingcharacterized as DIN Module 2. The outer housing 2100 and the inner gear2200 are positioned such that the gear teeth extending from the innersurface of the outer housing are positioned in a cooperating arrangementwith the gear teeth extending from the outer surface of the inner gear.A drive shaft 2230 provides suitable means for supplying rotation of theouter housing 2100. That is, appropriate connection of one end of thedrive shaft to the outer housing, and appropriate connection of theother end (not shown) of the drive shaft to a suitable power source (notshown) allows power supplied by the power source to provide rotation ofthe outer housing at the desired rate. Manners and methods forconnecting a drive shaft to the power source and other components of acigarette making machine are set forth previously with reference toFIGS. 5 through 9.

A fluid coating formulation (not shown) is introduced into the cavity2135 of the outer housing through entrance port 2240 from a source, suchas a tube (not shown), and the formulation can be pumped (or otherwisesupplied) from a supply reservoir (not shown). In use, the outer housingis rotated clockwise by rotation of the drive shaft 2230. The inner gearalso is rotated clockwise; and as such, the inner and outer components2200, 2100 also rotate relative to one another. Coating formulationwithin the reservoir region of the inner cavity is transferred to troughregions between adjacent teeth of the outer gear. That is, rotation ofthe outer gear within the housing, and the passage of a portion of thegear face of the inner gear through the reservoir region, results in theoutward forces that result in introduction of coating formulation to thetrough regions between the adjacent teeth of the outer housing. A scrape2250, plough, or other suitable means for removing excess coatingmaterial from the surface of the teeth of the outer housing ispositioned upstream from the pick-up region of the reservoir 2135.Typically, the scrape is positioned abut 0.5 mm from the upper surfaceof the gear teeth of the outer housing. The cooperation of the gearteeth of the two gears 2160, 2200 that rotate relative to one another issuch that during mating coating material in the trough regions 2300,2305 of adjacent teeth of certain gear teeth 2300, 2310 of the innergear with the gear teeth of the outer housing near the upper region 2312of the applicator system 70 forces or pumps the coating formulation (notshown) through the passageway 2115 and to the outer surface of the outerhousing 2100.

Referring to FIG. 11, there is shown the outer housing 2100 having agenerally circular outer roll face 2110. The outer housing includes sixpassageways 2115, 2120, 2350, 2124, 2355, 2126, and the gear teethlocated on the inner surface of that outer housing. Within the outerhousing is the reservoir region 2135, an inlet port 2240 for coatingformulation (not shown), the scrape 2250, and the mount 2357 or supportfor that scrape. Within the outer housing is the inner gear 2200. Thedrive shaft 2230 provides for rotation of the outer housing.

Referring to FIG. 12, there is shown various components of theapplicator apparatus 70. The application system 70 includes a bearinghousing 2400 for ball bearings 2410, an inner bearing spacer 2422, anouter bearing spacer 2428, and internal retaining ring 2433 and anexternal beveled retaining ring 2440. The system also includes a driveshaft 2230, the inner gear 2200 and the outer housing 2100. The gearteeth of the inner surface of the outer housing 2100 that are shown arethose that have been shaped so as to avoid churning of the fluid coatingformulation (not shown) within the reservoir 2135. A rear side plate ordisc 2450 and a front side plate or disc 2455 maintains a closed system.Inlet port 2240 to the inner cavity 2135 is provided through a passage2460 from a supply port 2462 from a source (not shown). The applicatorsystem also includes a needle bearing 2466, a gear mount 2470 for theinner gear 2200, thrust washers 2472, 2474, and a series of nuts, screwsor other suitable connection means for maintaining the variouscomponents in proper operative arrangement. The various components ofthe applicator system are manufactured from suitable materials, such asstainless steel, hardened carbon steel, or the like. The applicationsystem also includes a series of appropriately located seals, such aso-rings 2600, 2602, 2604, 2606. Appropriate seals can be manufacturedfrom Teflon-type materials, polyurethane-type materials, rubber-typematerials, or the like. The construction of the application system mostpreferably is such that coating formulation only exits that system fromdesired locations, such as the passageways, at the appropriate times.

Referring to FIG. 13, there is shown certain relevant components ofanother embodiment of additive applicator apparatus 70 representative ofone aspect of the present invention. Such an application system 70 isuseful for applying additive material (not shown) to a moving substrate,such as a continuously moving strip of paper web (not shown). Theapplication system 70 can replace those types of applicators describedpreviously with reference to FIGS. 5 through 9. That is, the applicatorsystem is similar in many regards to that applicator system set forthpreviously with reference to FIGS. 10 through 12, and the applicatorsystem can be positioned in those locations for applicator systems forthose cigarette making machines described previously with reference toFIGS. 1, 2 and 4.

The applicator system 70 includes an outer housing 2100 that has anouter roll face 2110. The outer housing has a generally circular shape,and the circumference of the roll face 2110 for the representativeembodiment shown is about 40.2 cm. The roll face or application facepossesses a several passageways 2115, 2120, 2124, 2126, and thosepassageways extend from the outer surface of the outer housing to withina central cavity or inner region 2135 of that outer housing 2100. Theshapes, dimensions, format and locations of the passageways can vary;and representative passageway configurations have been describedpreviously with reference to FIGS. 10 through 12. A drive shaft 2230provides suitable means for supplying rotation of the inner gear 2200.That is, appropriate connection of one end of the drive shaft to theouter housing, and appropriate connection of the other end (not shown)of the drive shaft to a suitable power source (not shown) allows powersupplied by the power source to provide rotation of the outer housing atthe desired rate. Manners and methods for connecting a drive shaft tothe power source and other components of a cigarette making machine areset forth previously with reference to FIGS. 5 through 9.

A plough 2700, scrape, or other suitable means for removing excesscoating material from the surface of the teeth of the outer housing ispositioned upstream from the pick-up region of the reservoir 2135. Inoperation, the cooperation of the gear teeth of the two gears 2160, 2200that rotate relative to one another is such that coating material in thetrough regions 2300, 2305 of adjacent teeth of certain gear teeth of theinner gear with the gear teeth of the outer housing near the upperregion 2312 of the application system 70 forces or pumps the coatingformulation (not shown) through the passageway 2115 and to the outersurface of the outer housing 2100.

Referring to FIG. 14, there is shown the outer housing 2100 thatincludes six passageways 2115, 2120, 2350, 2124, 2355, 2126, and thegear teeth located on the inner surface of that outer housing. Withinthe outer housing is the reservoir region 2135, an inlet port 2240 forcoating formulation (not shown), the plough 2700, and the mount orsupport 2720 for that plough. Within the outer housing is the inner gear2200. The drive shaft 2230 provides for rotation of the outer housing.

Referring to FIG. 15, there is shown there is shown various componentsof the applicator apparatus 70. The application system 70 includes abearing housing 2400 for ball bearings 2410, second ball bearings 2750,third ball bearings 2753, bearing spacer 2756, wind back seal 2759,internal retaining ring 2433, and an external beveled retaining ring2440. The system also includes a drive shaft 2230, the inner gear 2200and the outer housing 2100. The gear teeth of the inner surface of theouter housing 2100 that are shown are those that have been shaped so asto avoid churning of the fluid coating formulation (not shown) withinthe reservoir 2135. A front side plate or disc 2455 maintains a closedsystem. Inlet port 2240 to the inner cavity 2135 is provided through apassage 2460 from a supply port 2462 from a source (not shown). Theapplicator system also includes a needle bearing 2466, and a series ofnuts, screws or other suitable connection means for maintaining thevarious components in proper operative arrangement. The variouscomponents of the applicator system are manufactured from suitablematerials, such as stainless steel, hardened carbon steel, or the like.The application system also includes a series of appropriately locatedseals, such as o-rings 2600, 2602, 2604.

For the embodiments shown with reference to FIGS. 9 through 15, theamount of additive material applied to the continuous paper web can becontrolled with greater precision by holding the paper web firmly downagainst the outer housing during rotation of that housing. This can beaccomplished, for example, by use of a flexible moving belt (not shown).That is, a flexible continuous belt of appropriate width can bepositioned so as to form a type of arc that matches the general shape ofa portion of the peripheral face of the region of the outer housingwhere coating formulation is forced from the applicator system.Typically, a flexible belt can be applied under tension between two ormore guide posts (not shown) positioned to maintain the belt in place,or by other suitable means. As such, there is provided an arrangementwhereby force is applied generally downwards to the outer surface of thepaper web so as to counteract forces (e.g., those forces provided by theoutward pumping action of the applicator system and centrifugal forcesresulting from the high speed rotation of the outer housing) that havean undesirable tendency to force the paper web away from the outerhousing during operation of the applicator system.

The types of application systems described with reference to FIGS. 9through 15 can be used to apply coating formulations of the type havinga fluid form; and exemplary coating formulations that have fluid formscan have the form of liquids, syrups, pastes, emulsions, or dispersionsor slurries of solid materials within any of the foregoing. Thoseapplication systems are particularly useful for applying fluid coatingformulations that have a wide range of viscosities, but are particular,coating formulations having viscosities in the range of about 800,000centipoise to about 1,000,000 centipoise. The application systems can beused to apply coating formulations that are virtually solvent free. Forexample, a generally liquid-type of fluid coating formulationincorporating pre-polymer components can be applied to a paper web usingsuch an application system, and those components that have been appliedat desired locations on the paper web can be cured using suitableradiation curing systems of the type set forth hereinbefore withreference to FIGS. 3 and 4. The application systems also can be used toapply coating formulations of the type set forth in U.S. patentapplication Ser. No. 10/324,837, filed Dec. 20, 2002. For example, awater-based coating formulation can be applied to a paper web using suchan application system, and the formulation that has been applied atdesired locations on the paper web can be dried using the suitablemicrowave curing systems of the type set forth hereinbefore withreference to FIGS. 1, 2 and 4.

Referring to FIG. 16, there is shown a portion of a cigarette makingmachine assembly 8; and there also are shown relevant components ofanother representative additive applicator apparatus 70. Such anapplicator 70 is particularly useful for applying to a paper web 55certain types of viscous additive materials. Such additive materialsuseful in applications involving cigarette paper include, for example,paste-type formulations of additive materials having viscosities in therange of about 500,000 centipoise to about 2,500,000 centipoise.

Additive applicator 70 is an assembly that includes a pick-up 1720 and atransfer pressure roller 1725 (or back-up roller) mounted on each sideof an application roller 2800. Those rollers are mounted through a frontroller plate 1730 secured to the front exterior region of a cigarettemaking machine. Each of a plurality of rollers 1426, 1428, is fixedlymounted to the front roller plate 1730; and those rollers provide guidesfor a path over which the paper web 55 travels from a bobbin (not shown)to the additive applicator 70 and on to other regions of the cigarettemaking machine 8.

The pick-up roller 1720 (shown in phantom) is positioned within areservoir 1740 for the additive material (not shown). The reservoir ismaintained in place and secured to the front roller plate 1730 by bolts2810, 2812 or other suitable connection means. The reservoir 1740 isconnected to a source (not shown) of additive material (e.g., aformulation having the form of a paste), through port 2820 near the topregion of the reservoir 1740. As such, a source of additive material forthe pick-up roller 1720 is provided. If desired, the reservoir can beequipped with devices for monitoring the amount of additive materialthat is present within that reservoir, such as are describedhereinbefore with reference to FIG. 6. Typically, the additive materialis supplied through tubing (not shown), such as Tygon-type tubing, thatfeeds the reservoir 1740 through port 2820. The reservoir of theadditive applicator 70 provides a receptable for the additive materialto the point of deposit onto the pick-up roller 1720.

A doctor blade 2822 is positioned near the pick-up roller 1720 near thetop region of that roller. The doctor blade can be supported in a fixedposition relative to the roller, or the doctor blade can be adjustable,for example, by being mounted in so as to be moveable using micrometer2844. As such, the positioning of the doctor blade 2822 relative to theroll face of roller 1720 can be adjusted. Preferably, the doctor bladeis positioned in order that additive material that has been applied tothe roll face of the pick-up roller is provided in the desired amount.Typically, the doctor blade is positioned so as to provide a layer ofadditive material on the roll face of the pick-up roller that has thedesired thickness, both along the length and width of the roll face.Typically, the doctor blade 2822 is positioned about 0.001 to about0.002 inch from the surface of the roll face of pick-up roller 1720.After the additive material on the roll face of the pick-up roller hasbeen provided in the desired amount, that additive material istransferred from the pick-up roller to the face of appropriate die 2840of applicator roller 2800.

The pick-up roller 1720 preferably is manufactured from a material thatcan vary, but preferably is manufactured from an elastomeric typematerial, such as a polyurethane rubber type material, a natural gumrubber, ethylene-propylene diene monomer rubber, or the like. Anexemplary pick-up roller has a diameter of about 50 mm to about 100 mm.For the embodiment shown, the pick-up roller rotates counter-clockwisewithin the reservoir 1740, and additive material within the reservoir isdeposited on the surface of that roller.

The pick-up roller 1720 is in roll contact with a plurality ofprotruding applicator dies 2840, 2842, 2844, 2846 of application roller2800. The application roller dies preferably are of the generaldimension of the pattern of additive material that is desired to beapplied to the paper web 55. An exemplary application roller 2800 ismanufactured from stainless steel, elastomeric material, or acombination of those materials. For example, larger wheel portion of theapplicator roller can be manufactured from stainless steel, and theprotruding dies can be manufactured as replaceable inserts manufacturedfrom relatively soft elastomeric materials. Alternatively, the wheel anddie component parts of the applicator roller can be manufactured from ahard metal material, such as stainless steel. An exemplary applicatorroller has a diameter of about 50 mm to about 100 mm, and typicallyabout 85 mm; and possesses four protruding dies each of about 10 mm toabout 15 mm in height, about 22 mm to about 25 mm in width, and about 5mm to about 8 mm in circumferential length. Other sizes and shapes ofthe dies, other configurations of the dies on the roller, other rollersizes, and the composition of components used to manufacture the roller,can be a matter of design choice. For the embodiment shown, applicationroller 2800 rotates clockwise.

In a preferred embodiment, each roller 1725, 2800 is drivenindependently. For example, one servo drive (not shown) can control therotation of transfer roller 1725, and a second servo drive (not shown)can control the applicator roller 2800. Controlling operation of the tworollers 1725, 2800 with independent servo system allow for independentcontrol of speeds of those two rollers, and hence, the ability totightly control the tolerances associated with application of additivematerial to the paper web using those two rollers. Rollers that areindependently adjustable also are preferred in that the degree oftouching of the roll faces of the respective rollers during roll contactcan be controlled.

In operation, the continuous paper web 55 passes between the roll facesof the transfer roller 1725 and the application roller 2800. As a resultof the such contact, the forces experienced by the paper web 55 as ittravels between the roll faces of the transfer pressure roller 1725 andthe applicator roller 2800, additive material transferred to thesurfaces of the protruding dies 2840, 2842, 2844, 2846 from the surfaceof the applicator roller 1720 is applied to the paper web 55 in apredetermined pattern. As such, the die faces provide a type of off-setprinting of additive material to desired locations on the moving paperweb. Movement of the transfer pressure roller 1725 can programmed, andas such a microprocessor associated with the operation of the cigarettemaking machine. Such control by a signal received from the cigarettemaking machine can allow for retraction of the pressure roller from thepaper web 55 so as to not be in contact with the various rollers whenthe cigarette making machine is not in normal operation; and as such,problems associated with sticking of the paper web to various componentsof the applicator apparatus 70 are minimized, avoided or prevented.

Referring to FIG. 17, there is shown a portion of a cigarette makingmachine assembly 8; and there also are shown relevant components ofanother representative additive applicator apparatus 70. Such anapplicator 70 is particularly useful for applying to a paper web 55certain types of viscous additive materials. Such additive materialsuseful in applications involving cigarette paper include, for example,paste-type formulations of additive materials having viscosities in therange of about 500,000 centipoise to about 2,500,000 centipoise.

Additive applicator 70 is an assembly that includes a pick-up 1720 inroll contact with an applicator roller 2800. Those rollers are mountedthrough a front roller plate 1730 secured to front exterior of acigarette making machine. Each of a plurality of rollers 1422, 1426, isfixedly mounted to the front roller plate 1730; and those rollersprovide guides for a path over which the paper web 55 travels from abobbin (not shown) to the additive applicator 70 and on to other regionsof the cigarette making machine 8.

The pick-up roller 1720 (shown in phantom) is positioned within areservoir 1740 for the additive material (not shown). The reservoir ismaintained in place and secured to the front roller plate 1730 by bolts2810, 2812 or other suitable connection means. The reservoir 1740 isconnected to a source (not shown) of additive material (e.g., aformulation having the form of a paste), through port 2820 near the topregion of the reservoir 1740. As such, a source of additive material forthe pick-up roller 1720 is provided. Typically, the additive material issupplied through tubing (not shown), such as Tygon-type tubing, thatfeeds the reservoir 1740 through port 2820.

A doctor blade 2822 is positioned near the pick-up roller 1720 near thetop region of that roller. The doctor blade can be mounted in a fixedposition relative to the roll face of the roller. The doctor blade alsocan be adjustable, for example, by being positioned so as to be movableusing a micrometer 2844. As such, the positioning of the doctor blade2822 relative to the roll face of roller 1720 can be adjusted.Preferably, the doctor blade is positioned in order that additivematerial that has been applied to the roll face of the pick-up roller isprovided in the desired amount. Typically, the doctor blade ispositioned so as to provide a layer of additive material on the rollface of the pick-up roller that has the desired thickness, both alongthe length and width of the roll face. Typically, the doctor blade 2822is positioned about 0.001 to about 0.002 inch from the surface of theroll face of pick-up roller 1720. After the additive material on theroll face of the pick-up roller has been provided in the desired amount,that additive material is transferred from the pick-up roller to theface of appropriate location on the paper web 55.

The pick-up roller 1720 preferably is manufactured from a material thatcan vary, can be a soft material or a hard material, but preferably ismanufactured from an elastomeric type material, such as a polyurethanerubber type material, or other suitable material. An exemplary pick-uproller is described previously with reference to FIG. 16. The pick-uproller rotates clockwise (for the embodiment shown) within the reservoir1740, and additive material within the reservoir is deposited on thesurface of the roll face of that roller.

The pick-up roller 1720 is in roll contact with protruding applicatorcams 2840, 2842, 2844, 2846 of application roller 2800. The applicationroller cams are of the general dimension of the pattern of additivematerial that is desired to be applied to the paper web 55. An exemplaryapplication roller 2800 is described previously with reference to FIG.16. For the embodiment shown, application roller 2800 rotatescounter-clockwise.

In a preferred embodiment, each roller 1725, 2800 is drivenindependently. For example, one servo drive (not shown) can control therotation of transfer roller 1725, and a second servo drive (not shown)can control the applicator roller 2800. Controlling operation of the tworollers 1725, 2800 with independent servo system allow for independentcontrol of speeds of those two rollers, and hence, the ability totightly control the tolerances associated with application of additivematerial to the paper web using those two rollers.

In operation, the continuous paper web 55 passes between the roll facesof the pick-up roller 1720 and the application roller 2800. As a resultof the contact experienced by the paper web 55 as it travels betweenpick-up roller 1720 and the applicator roller 2800, additive materialtransferred to the surfaces of the protruding cams 2840, 2842, 2844,2846 from the surface of the applicator roller 1720 is applied to thepaper web 55 in a predetermined pattern. That is, the protrudingapplicator roller cams on the side of paper web, opposite the pick-uproller and the additive material, cause periodic deflection of the paperweb toward the pick-up roller; and as such, additive material istransferred from the surface of the pick-up roller to the paper web in acontrolled manner as a result of the camming action of the applicatorroller. The paper web 55 is routed in a manner such that the paper webhas a tendency to move upwards and away from the surface of theapplicator pick-up roller when the various cams are not deflecting thatpaper web downwards. As a result, control of the location of theapplication of additive material on the paper web can be carried out.

Referring to FIG. 18, there are shown relevant components of a portionof yet another representative additive applicator apparatus 70. Such anapplicator can be used to provide coating formulation to the movingpaper web 55 (partially shown and cut away) in a non-contact manner.Such an applicator can be used to apply additive formulation that isejected onto the paper web, such as is set forth hereinbefore withreference to FIGS. 3 and 4. Appropriate cigarette making assemblies (notshown) can be equipped with one applicator of such a type, or two ormore applicators of such a type can be employed in series.

The applicator apparatus 70 possesses an outer housing 3000 having agenerally wheel-like shape. The outer housing has a roll face 3015. Aplurality of printheads 3035, 3037, 3039 are arranged at pre-determinedlocations on the roll face 3015. Preferred printheads are ink jet typesof printheads, for example, of the type described previously withreference to FIGS. 3 and 4.

For the embodiment shown, the outer housing is adapted to rotatecounter-clockwise; in the direction indicated by arrow 3050. A strip ofpaper web 55 travels over at least the top surface of the roll face 3015of the housing 3000, in the direction indicated by arrow 3055. Thedesired path of travel of the paper web 55 is dictated by suitablypositioned idler rollers 3057, 3059, or other appropriate means.Alternatively, for an embodiment that is not shown, the path of travelof the paper web 55 can be underneath of the housing 3000 and can be inthe same overall direction as arrow 3055; and for such an embodiment,the housing 3000 is rotated in the direction opposite of arrow 3050.Thus, for the two embodiments so described, additive material can beapplied to either side of a continuous strip of paper web.

Most preferably, the printheads 3035, 3037, 3039 are recessed slightlyfrom the surface of the outer roll face of the housing in order that thepaper web traveling over the roll face does not come into contact withthose printheads. As such, non-contact application of coatingformulation (not shown) to the paper web can be carried out.

The wheel-like housing 3000 is supported on by a suitable frame, such asis provided by front support 3060 and back support 3062. Each support islocated on either side of the housing. Each support incorporatessuitable bearing assemblies (not shown) or other suitable means forallowing the housing to rotate relative to those supports.

The housing is supplied with additive material (not shown) from asuitable supply source (not shown) using a rotary union 3070 or othersuitable fluid material supply means. Suitable unions are thoseavailable as Deublin ⅛″ to ½″ Air-Hydraulic Unions from Deublin Company.As such, additive material is supplied to the inner region of thehousing 3000, and thereafter, the additive material can be supplied tothe printheads 3035, 3037, 3039.

Control of the rotation of the housing and of the operation of thevarious printheads is provided from a remote location (not shown)through wire 3080 or other appropriate connection means that are in turnconnected to a slip ring 3085. Suitable slip rings are those high-speedslip rings available from International Instruments, Inc. As such,during rotation of the housing, electronic control of the printheads canbe achieved, and additive material from the rotary union also can besupplied to the various printheads.

In operation, the paper web 55 is advanced over the top region of theapplicator roll face 3015. The applicator is rotated, and is rotated ata rate such that application of additive material from each individualprinthead provides the desired pattern on the paper web in the desiredlocation on that paper web. As such, ejection of additive material isapplied as both the applicator nozzles and the paper web both are movingat high rate of speed, and for the most highly preferred embodiments, atessentially identical speeds. Thus, non-contact ink jet types oftechnologies can be used to effectively apply ejected additive materialsto pre-determined locations and in pre-determined patterns onto acontinuous strip of paper web moving at a very high rate of speed.

The various aspects of the present invention, whether employedindividually or in some combination, offer several advantages andimprovements to conventional systems and methods for cigarettemanufacture. The present invention allows a cigarette manufacturer toapply predetermined and discrete amounts of an additive material to acontinuous advancing strip of a paper web at desired locations on thatpaper web, during the manufacture of a continuous cigarette rod usingconventional types of cigarette making equipment and methodologies. Ofparticular interest are bands of additive material that are positionedperpendicularly to the longitudinal axis of the paper web, and thosebands can be positioned so as to extend across less than the total widthof that paper web. As such, the location of additive material can becontrolled so as to not be located in the lap zone of the continuouscigarette rod (e.g., where the side seam adhesive is applied). Thus, forexample, a continuous paper web having a width of about 27 mm and usedto provide a cigarette rod having a circumference of about 24.5 mm(i.e., such that the lap zone has a width of about 2.5 mm) can have aband applied to that web such that the band is not located within thelap zone where side seam adhesive is applied; and as such, such a bandcan have a transversely extending length of about 22 mm to about 24.5mm. The present invention allows a cigarette manufacturer to apply topaper webs additive formulations that have a wide range of chemical andphysical properties, and that are provided for application in a widevariety of forms (e.g., a wide range of viscosities). In addition, thepresent invention allows a manufacturer of cigarettes to apply additivematerials to paper webs without adversely affecting the physicalproperties and integrity of that paper web to any significant degree.Registration of patterns (e.g., bands) applied to the paper wrappingmaterials of tobacco rods promotes the ability of cigarettemanufacturers to provide consistent quality cigarette rods, and theability to control the properties of cigarettes through on-lineproduction techniques offers advantages over cigarettes that aremanufactured using pre-printed paper wrapping materials. The presentinvention also provides a manufacturer of cigarettes with the ability toensure the production of high quality cigarettes with applied patternsregistered in the desired locations of those cigarettes.

The paper wrapping material that is further processed to provide thepatterned wrapping material can have a wide range of compositions andproperties. The selection of a particular wrapping material will bereadily apparent to those skilled in the art of cigarette design andmanufacture. Typical paper wrapping materials are manufactured fromfibrous materials, and optional filler materials, to form so-called“base sheets.” Wrapping materials of the present invention can bemanufactured without significant modifications to the productiontechniques or processing equipment used to manufacture those wrappingmaterials.

Typical wrapping material base sheets suitable for use as thecircumscribing wrappers of tobacco rods for cigarettes have basisweights that can vary. Typical dry basis weights of base sheets are atleast about 15 g/m², and frequently are at least about 20 g/m²; whiletypical dry basis weights do not exceed about 80 g/m², and frequently donot exceed about 60 g/m². Many preferred wrapping material base sheetshave basis weights of less than 50 g/m², and even less than 40 g/m².Certain preferred paper wrapping material base sheets have basis weightsbetween about 20 g/m² and about 30 g/m².

Typical wrapping material base sheets suitable for use as thecircumscribing wrappers of tobacco rods for cigarettes have inherentporosities that can vary. Typical base sheets have inherent porositiesthat are at least about 5 CORESTA units, usually are at least about 10CORESTA units, often are at least about 15 CORESTA units, and frequentlyare at least about 20 CORESTA units. Typical base sheets have inherentporosities that are less than about 200 CORESTA units, usually are lessthan about 150 CORESTA units, often are less than about 85 CORESTAunits, and frequently are less than about 70 CORESTA units. A CORESTAunit is a measure of the linear air velocity that passes through a 1 cm²area of wrapping material at a constant pressure of 1 centibar. See,CORESTA Publication ISO/TC0126/SC I N159E (1986). The term “inherentporosity” refers to the porosity of that wrapping material itself to theflow of air. A particularly preferred paper wrapping material base sheetis composed of wood pulp and calcium carbonate, and exhibits an inherentporosity of about 20 to about 50 CORESTA units.

Typical paper wrapping material base sheets suitable for use as thecircumscribing wrappers of tobacco rods for cigarettes incorporate atleast one type of fibrous material, and can incorporate at least onefiller material, in amounts that can vary. Typical base sheets includeabout 55 to about 100, often about 65 to about 95, and frequently about70 to about 90 percent fibrous material (which most preferably is acellulosic material, such as wood pulp); and about 0 to about 45, oftenabout 5 to about 35, and frequently about 10 to about 30 percent fillermaterial (which most preferably is an inorganic material, such ascalcium carbonate); based on the dry weight of that base sheet. Basesheets can have various additive materials incorporated therein, and thebase sheets can be physically treated (e.g., the base sheets can beelectrostatically perforated). Exemplary fibrous materials, fillermaterials, additives and physical treatments of papers are set forth inU.S. patent application Ser. No. 10/303,648, filed Nov. 25, 2002 andSer. No. 10/324,837, filed Dec. 20, 2002, which are incorporated hereinby reference in their entireties. See, also, US Patent Application2003/0089377 to Hajaligol et al.

Typical paper wrapping materials that can be used in carrying out thepresent invention are manufactured under specifications directed towardthe production of a wrapping material having an overall generallyconsistent composition and physical parameters. For those types ofwrapping materials, the composition and parameters thereof preferablyare consistent when considered over regions of each of the majorsurfaces of those materials. However, typical wrapping materials tend tohave a “two-sided” nature, and thus, there can be changes in thecomposition and certain physical parameters of those materials from onemajor surface to the other.

Though less preferred, the wrapping material can be manufactured using apaper making process adapted to provide a base web comprising multiplelayers of cellulosic material. See, U.S. Pat. No. 5,143,098 to Rogers etal.

Much less preferred paper wrapping materials can have compositionsand/or properties that differ over different regions of each of theirmajor surfaces. The wrapping material can have regions of increased ordecreased porosity provided by control of the composition of thatmaterial, such as by controlling the amount or type of the filler. Thewrapping material can have regions of increased or decreased airpermeability provided by embossing or perforating that material. See,for example, U.S. Pat. No. 4,945,932 to Mentzel et al. The wrappingmaterial can have regions (e.g., pre-determined regions, such as bands)treated with additives, such as certain of the aforementioned salts.However, wrapping materials having a patterned nature are not necessarywhen various aspects of the present invention are used to apply patternsto those wrapping materials using on-line pattern applicationtechniques.

Paper wrapping materials suitable for use in carrying out the presentinvention (e.g., suitable for use as wrapping materials for smokablematerials and for the manufacture of cigarette rods) are commerciallyavailable. Representative cigarette paper wrapping materials have beenavailable as Ref. Nos. 419, 454, 456, 460 and 473 Ecusta Corp.; Ref.Nos. Velin 413, Velin 430, VE 825 C20, VE 825 C30, VE 825 C45, VE 826C24, VE 826 C30 and 856 DL from Miquel; Tercig LK18, Tercig LK24, TercigLK38, Tercig LK46 and Tercig LK60 from Tervakoski; and Velin Beige 34,Velin Beige 46, Velin Beige 60, and Ref. Nos. 454 DL, 454 LV, 553 and556 from Wattens. Exemplary flax-containing cigarette paper wrappingmaterials have been available as Grade Names 105, 114, 116, 119, 170,178, 514, 523, 536, 520, 550, 557, 584, 595, 603, 609, 615 and 668 fromSchweitzer-Mauduit International. Exemplary flax-containing cigarettepaper wrapping materials having relatively high levels of chemicaladditives have been available as Grade Names 512, 525, 527, 540, 605 and664 from Schweitzer-Mauduit International. Exemplary woodpulp-containing cigarette paper wrapping materials have been availableas Grade Names 404, 416, 422, 453, 454, 456, 465, 466 and 468 fromSchweitzer-Mauduit International. Exemplary wood pulp-containingcigarette paper wrapping materials having relatively high levels ofchemical additives have been available as Grade Names 406 and 419 fromSchweitzer-Mauduit International.

The composition of the additive material or coating formulation canvary. Generally, the composition of the coating is determined by theingredients of the coating formulation. Preferably, the coatingformulation has an overall composition, and is applied in a manner andin an amount, such that the physical integrity of the wrapping materialis not adversely affected when the coating formulation is applied toselected regions of the wrapping material. It also is desirable thatcomponents of the coating formulation not introduce undesirable sensorycharacteristics to the smoke generated by a smoke article incorporatinga wrapping material treated with that coating formulation. Thus,suitable combinations of various components can act to reduce the effectof coatings on sensory characteristics of smoke generated by the smokingarticle during use.

A coating formulation can have a liquid, syrup or paste form, and isapplied as such. Depending upon the actual ingredients that are combinedwith the solvent, the coating formulation has the form of a liquid typeof solution or of a liquid having solid materials dispersed therein.Certain other optional ingredients also are dissolved, dispersed orsuspended in that formulation. Additionally, optional filler materialalso is dispersed within that formulation. Preferably, the fillermaterial is essentially insoluble and essentially chemicallynon-reactive with the solvent, at least at those conditions at which theformulation is employed. For example, the material does not undergosignificant undesirable chemical reaction when subjected to heat orradiation during the process conditions of the present invention.

The coating formulation most preferably includes a material thatprovides a film or otherwise acts as a film-forming agent. Suitablecombinations of various film-forming agents also can be employed.Materials in the form of films have a tendency to adhere to a papersubstrate, maintain other components of the coating formulations inplace, and have the ability to lower the inherent porosity of the papersubstrate and otherwise have an effect upon the performancecharacteristics of a cigarette incorporating such a treated paper.

In certain aspects of the present invention, the film-forming agent mostpreferably is a polymeric material or resin; and such a film-formingagent is applied to the desired location on the surface of a cigarettepaper substrate within a solvent or liquid carrier. As such, a solutionor dispersion of a coating formulation is applied to the substrate, andafter removal of solvent or liquid carrier, the film-forming agent driesto form a film on that substrate. Exemplary polymeric film-formingagents include water soluble polymeric materials, such as starches.

In certain aspects of the present invention, the film-forming agent isapplied to the desired location on the surface of a cigarette papersubstrate as part of a coating formulation that is virtually absent of asolvent or liquid carrier (e.g., the coating formulation can becharacterized as being 100 percent solids in nature). Certain coatingformulations that have been applied to the desired location on thesurface of a cigarette paper substrate using contact applicationtechniques. Contact application techniques involve the use of the rollapplicator techniques set forth hereinbefore, or other suitabletechniques, such as screen printing types of techniques. Screen printingtechnology is described in US Patent Application 2001/0042456 to Kamenet al., which is incorporated herein by reference. Suitable non-contactapplication techniques (e.g., ink jet type printing techniques) also canbe used to apply coating formulations to the paper substrate. Then,those formulations are subjected to exposure to an effective amount ofradiation in order to polymerize (e.g., cross-link) certain componentsof those formulations, and to ensure fixing or adherence of thecomponents of those formulations to the desired locations on the papersubstrate. As such, the polymerizable components of those coatingformulations are subjected to electromagnetic radiation capable ofinitiating photochemical reactions. Effective initiation of chemicalreactions between those polymerizable components that have an overallliquid form results in polymerization (e.g., cross-linking reactions) ofthose components, and a resultant curing or solidification ofpolymerizable components.

Exemplary radiation curable polymerizable compositions are thosecompositions that comprise free radical polymerizable components (e.g.,free radical addition polymerizable components), and most preferably,compounds having terminal ethylenic unsaturation that are overall liquidin nature under those types of conditions under which thosepolymerizable compositions are handled and used. Such exemplarycompositions are referred to as “pre-polymer compositions,” andtypically comprise monomeric diluents that can be combined witholigomers, preformed polymers, or combinations of oligomers or preformedpolymers. A monomeric diluent is a lower molecular weight compound(e.g., a lower molecular weight ethylenically unsaturated compound) thatis a reactant in a polymerization reaction directly upon initiation byfree radicals generated upon absorption of radiation. Typically, anexemplary monomeric diluent is comprised of at least one monomericcompound having at least one terminal ethylenically unsaturated moiety.Alternatively, pre-polymer compositions can comprise condensationpolymerizable components and suitable cross-linking agents. For example,pre-polymer compositions comprising mixtures of cellulosic-typematerials and epoxides can be employed.

Representative types of monomic compounds, diluents, oligomers andpreformed polymers, techniques for applying those materials tosubstrates, and techniques for curing those materials using radiation,are set forth in U.S. Pat. No. 5,563,644 to Isganitis et al. and U.S.Pat. No. 6,232,361 to Laksin et al.; PCT WO 00/56554 and PCT WO02/08309; US Patent Applications 2001/0042456 to Kamen et al.;2002/0004132 to Banovetz et al.; 2003/0004223 to Khudyakov et al.;2003/0031843 to Wu et al.; 2003/0032692 to Mejiritski et al.;2003/0064201 to Xing et al.; 2003/0069363 to Greenblatt et al. and2003/0073755 to Garnett et al.; and US Stat. Inv. Reg. H1517 to Ericksonet al.; which are incorporated herein by reference.

Suitable radiation curable materials are available commercially fromsources such as Sartomer Company, Inc., Sun Chemical Corporation (e.g.,as products designated as Sunbeam LE); Rohm & Haas Company and LiofolCompany. Exemplary pre-polymer components that are suitable forproviding coatings on paper webs incorporate polymerized ethylene-typematerials, polymerized propylene-type materials, polymerized ethylenevinylacetate-type formulations, polymerized ethylene acrylic acid-typeformulations, polymerized ethylene methacrylic acid-type formulations,polyvinyl alcohol formulations, polystyrene formulations, polyethyleneformulations, polypropylene formulations, and the like. Exemplarypre-polymer components that are suitable for providing coatings on paperwebs incorporate suitable cross-linking agents with low molecular weightpolyesters, low molecular weight cellulosics (e.g., ethylcellulose ornitrocellulose), low molecular weight polyurethanes, low molecularweight nylons, and the like.

Coating formulations incorporating pre-polymer compositions canincorporate at least one initiator. Initiators are used when suchcoating formulations are cured using uv radiation, and optionally can beused to some degree when such coating formulations are cured usingelectron beam radiation. Initiators can be characterized as free radicalor cationic. Examples suitable initiators are the peroxide-typeinitiators that include the diacyls, peroxydicarbonates,monoperoxycarbonates, peroxyketals, peroxyesters, dialkyl peroxides andhydroperoxides. Initiators are commercially available, such as LuperoxF, Luperox DC, Luperox 130, Luperox 801 Luperox 230 and Luperox 231 fromSpecialChem S. A. The amount of initiator that is employed can vary, andis dependent upon factors such as the pre-polymer material that issubjected to radiation for cure. Typically, for uv curable pre-polymercompositions, the amount of initiator ranges from about 0.5 to about 6percent, and often about 1 to about 3 percent, based on the weight ofthe pre-polymer composition within the coating formulation. Numerousinitiators are set forth in those references that has been citedhereinbefore, and that disclose various radiation curable monomiccompounds, diluents, oligomers and preformed polymers, techniques forapplying those materials to substrates, and techniques for curing thosematerials using radiation. Certain water-based uv curable systems usinguv photoinitiators are set forth in U.S. Pat. No. 5,623,001 to Figov,which is incorporated herein by reference.

Certain additive materials can be applied to the wrapping material inthe form of a coating formulation that is in a so-called “solid polymer”form. Such coating formulations can be applied using contact applicationtechniques or non-contact application (e.g., electrostatic deposition)techniques. That is, film-forming materials, such as ethylene vinylacetate copolymers and certain starches, can be mixed with othercomponents of the coating formation, and applied to the wrappingmaterial without the necessity of dissolving those film-formingmaterials in a suitable solvent. Typically, solid polymer coatingformulations are applied at elevated temperatures relative to ambienttemperature; and the viscosities of the film-forming materials of thoseheated coating formulations typically have an extremely wide range ofviscosities. Certain preferred heated solid polymer coating formulationshave viscosities of about 1000 to about 5000 centipoise. Other exemplarycomponents that are suitable for providing coatings for paper web arethose that incorporate low molecular weight polymers and resins.Examples of polymers and resins include polyesters (e.g., polyesterterephlalate), cellulosics (e.g., ethylcellulose and nitrocellulose),polyolefins (e.g., polyethylene and polypropylene), polyurethanes,nylons, polyvinyl alcohol, polyaromatics (e.g., polystyrene),polyethylene vinylacetate, polyethylene acrylic acid, polyethylenemethacrylic acid, and the like.

Certain coating formulations that are used in carrying out certainaspects of the present invention can incorporate liquid solvents, suchas a liquid having an aqueous character as is set forth in Ser. No.10/324,837, filed Dec. 20, 2002. However, typical coating formulationsuseful for carrying out certain aspects of the present invention (i.e.,those aspects that relate to the use a radiation curable coatingformulations or electrostatic deposition formulations) contain less thanabout 15 percent, preferably less than about 10 percent, more preferablyless than about 5 percent, and most preferably about 0 percent, solventor liquid carrier, based on the total weight of the coating formulationjust prior to application. Representative solvents and liquid carriersare liquids having aqueous characters, and can include relatively purewater; or non-aqueous liquid solvents, such as ethanol, n-propylalcohol, iso-propyl alcohol, ethyl acetate, n-propyl acetate, iso-propylacetate, toluene, and the like. It is preferred that the radiationcurable coating formulation contain a relatively low amount of solventor liquid carrier; it is highly preferred that such a coatingformulation be essentially absent of solvent or liquid carrier; and itis most highly preferred that the coating formulation be virtually freeof (i.e., not contain any) solvent or liquid carrier. Exemplary solventsand liquid carriers, and representative amounts of those solvents andliquid carriers used for coating formulations containing relatively highlevels of those solvents and liquid carriers, are set forth in U.S.patent application Ser. No. 10/303,648, filed Nov. 25, 2002 and Ser. No.10/324,837, filed Dec. 20, 2002.

The coating formulation also can include a filler material. Exemplaryfiller materials can be the essentially water insoluble types of fillermaterials of the type described in U.S. patent application Ser. Nos.10/303,648, filed Nov. 25, 2002. See, also, US Patent Application2003/0089377 to Hajaligol et al. Preferred filler materials have afinely divided (e.g., particulate) form. Typical fillers are those thathave particle sizes that are less than about 3 microns in diameter.Typical particle sizes of suitable fillers range from about 0.3 micronto 2 microns in diameter. The filler materials can have a variety ofshapes. Exemplary filler materials are those that are composed ofinorganic materials including metal particles and filings, calciumcarbonate (e.g., precipitated-type fillers, including those having aprismatic form), calcium phosphate, clays (e.g., attapulgite clay),talc, aluminum oxide, mica, magnesium oxide, calcium sulfate, magnesiumcarbonate, magnesium hydroxide, calcium phosphate, aluminum oxide andtitanium dioxide. See, for example, the types of filler materials setforth in U.S. Pat. No. 5,878,753 to Peterson et al. Representativecalcium carbonate fillers are those available as Albacar PCC, AlbafilPCC, Albaglos PCC, Opacarb PCC, Jetcoat PCC and Calopake F PCC fromSpecialty Minerals, Inc. Exemplary filler materials also can be composedof natural or synthetic organic materials including starches, modifiedstarches and flours (e.g., rice flour), particles of polyvinyl alcohol,particles of tobacco (e.g., tobacco dust), and other like materials. Thefiller material also can be fibrous cellulosic materials. See, forexample, U.S. Pat. No. 5,417,228 to Baldwin et al. Although lesspreferred, alternate fillers can include carbon-based materials (e.g.,graphite-type materials, carbon fiber materials and ceramics), metallicmaterials (e.g., particles of iron), and the like. The filler materialalso can be a water soluble salt (e.g., potassium chloride, sodiumchloride, potassium citrate, sodium citrate, calcium chloride ormagnesium chloride). Exemplary salts are set forth in U.S. Pat. No.4,622,983 to Mathews; U.S. Pat. No. 4,941,485 to Perfetti et al; andU.S. Pat. No. 5,220,930 to Gentry.

The coating formulations can incorporate other ingredients in additionto the aforementioned coating materials; and those ingredients can bedispersed or suspended within the coating formulation. Those otheringredients can be employed in order to provide specific properties orcharacteristics to the wrapping material. Those ingredients can bepreservatives (e.g., potassium sorbate), humectants (e.g., ethyleneglycol and propylene glycol), pigments, dyes, colorants, burn promotersand enhancers, burn retardants and inhibitors, plasticizers (e.g.,dibutyl phthalate, polyethylene glycol, polypropylene glycol andtriacetin), sizing agents, syrups (e.g., high fructose corn syrup),flavoring agents (e.g., ethyl vanillin and caryophyllene oxide), sugars(e.g., rhamnose), flavor precursors, hydrate materials, such as metalhydrates (e.g., borax, magnesium sulfate decahydrate, sodium silicatepentahydrate and sodium sulfate decahydrate), viscosity reducing agents(e.g., urea), and the like. Nanoparticle materials can be incorporatedinto such coating formulations, such as is set forth in U.S. patentapplication Ser. No. 10/342,618, filed Jan. 15, 2003, which isincorporated herein by reference. If desired, the coating formulationscan contain dyes or pigments for aesthetic purposes (e.g., thosecomponents can provide white, black, gray, blue or brown colors) or tofacilitate automated inspection of paper wrapping materials to which theformulations are applied.

For a coating formulation that employs a liquid solvent or carrier, theamount of such solvent or liquid carrier typically makes up about atleast about 20 percent of the formulation, and often makes up at leastabout 30 percent of the formulation, based on the weight of theformulation. Most preferably, such a coating formulation includes atleast about 0.5 percent film-forming agent, usually at least about 1percent film-forming agent, and often at least about 2 percentfilm-forming agent, based on the total weight of that formulation.Typically, the amount of film-forming agent within such a coatingformulation does not exceed about 60 percent, usually does not exceedabout 50 percent, and often does not exceed about 40 percent, based onthe total weight of that formulation. Typically, the coating formulationincludes at least about 3 percent of the optional filler material,usually at least about 5 percent filler material, and often at leastabout 10 percent filler material, based on the total weight of thatformulation. Typically, the amount of optional filler material withinthe coating formulation does not exceed about 35 percent, usually doesnot exceed about 30 percent, and often does not exceed about 25 percent,based on the total weight of that formulation.

For a coating formulation that employs a radiation curable pre-polymerformulation, the relative amounts of the various components of thatformulation can vary. Most preferably, such a coating formulationincludes at least about 5 percent material that is cured to provide thefilm-forming agent, usually at least about 10 percent of that agent, andoften at least about 15 percent of that agent, based on the total weightof that formulation. The material that is cured to form the film-formingagent can comprise approximately all (i.e., about 100 weight percent) ofthe coating formulation. Typically, the amount of film-forming agentwithin such a coating formulation does not exceed about 30 percent,usually does not exceed about 20 percent, and often does not exceedabout 15 percent, based on the total weight of that formulation.Typically, the coating formulation includes at least about 50 percent ofthe optional filler material, usually at least about 60 percent fillermaterial, and often at least about 70 percent filler material, based onthe total weight of that formulation. Typically, the amount of optionalfiller material within the coating formulation does not exceed about 80percent, usually does not exceed about 50 percent, and often does notexceed about 40 percent, based on the total weight of that formulation.

For a coating formulation that is applied using electrostatic depositiontechniques, the relative amounts of the various components of thatformulation can vary. Most preferably, such a coating formulationincludes at least about 30 percent film-forming agent, usually at leastabout 50 percent film-forming agent, and often at least about 80 percentfilm-forming agent, based on the total weight of that formulation.Typically, the amount of film-forming agent within such a coatingformulation can make up all of the formulation, but typically does notexceed about 95 percent, and often does not exceed about 90 percent, ofthe total weight of that formulation. Typically, the coating formulationincludes at least about 5 percent of the optional filler material,usually at least about 10 percent filler material, and often at leastabout 20 percent filler material, based on the total weight of thatformulation. Typically, the amount of optional filler material withinthe coating formulation does not exceed about 70 percent, and usuallydoes not exceed about 50 percent, based on the total weight of thatformulation.

The amounts of other optional components of the various coatingformulations can vary, depending upon factors such as the type ofcoating formulation that is employed and the desired properties of thecoated substrate. When employed, the amount of plasticizer often rangesfrom about 0.5 percent to about 5 percent, preferably about 2 to about 3percent, based on the total weight of the formulation. When employed,the amount of humectant often ranges from about 1 percent to about 5percent, preferably about 2 to about 3 percent, based on the totalweight of the formulation. When employed, the amount of wetting agentoften ranges from about 0.5 percent to about 2 percent, preferably about0.8 to about 1 percent, based on the total weight of the formulation.When employed, the amount of preservative often ranges from about 0.01percent to about 0.3 percent, preferably about 0.5 percent, based on thetotal weight of the formulation. When employed, the amount of burnchemical often ranges from about 1 percent to about 15 percent,preferably about 5 to about 10 percent, based on the total weight of theformulation. When employed, the amount of viscosity reducing agent oftenranges from about 1 percent to about 10 percent, preferably about 2percent to about 6 percent, based on the total weight of theformulation. When employed, the amount of metal hydrate often rangesfrom about 3 percent, usually at least about 5 percent, and often atleast about 10 percent, based on the total weight of that formulation;but the amount of metal hydrate usually does not exceed about 35percent, often does not exceed about 30 percent, and frequently does notexceed about 25 percent, based on the total weight of that formulation.

Flavoring agents can be incorporated into the coating formulations.Preferably, the flavoring agents exhibit sensory characteristics thatcan be described as having notes that are sweet, woody, fruity, or somecombination thereof. The flavoring agents preferably are employed inamounts that depend upon their individual detection thresholds.Typically, the flavoring agents are employed in sufficient amounts so asto mask or ameliorate the off-tastes and malodors associated withburning paper. Combinations of flavoring agents (e.g., a flavor package)can be employed in order to provide desired overall sensorycharacteristics to smoke generated from the smoking articlesincorporating those flavoring agents. Most preferably, those flavoringagents are employed in amounts and manners so that the sensorycharacteristics of those flavoring agents are hardly detectable; andthose flavoring agents do not adversely affect the overall sensorycharacteristics of smoking article into which they are incorporated.Preferred flavoring agents can be incorporated into printingformulations, have low vapor pressures, do not have a tendency tomigrate or evaporate under normal ambient conditions, and are stableunder the processing conditions experienced by wrapping materials of thepresent invention. Exemplary flavoring agents that provide sweet notesinclude ethyl vanillin, vanillin, heliotropin, methylcyclopentenolone;and those flavoring agents typically are employed in amounts of 0.001 toabout 0.01 percent, based on the total weight of the coating formulationinto which they are incorporated. An exemplary flavoring agent thatprovides woody notes includes caryophyllene oxide; and that flavoringagent typically is employed in amounts of 0.2 to about 0.6 percent,based on the total weight of the coating formulation into which it isincorporated. Exemplary flavoring agents that provide fruity notesinclude ketones such as 4-hydroxphenyl-2-butanone and lactones such asgamma-dodecalactone; and those flavoring agents typically are employedin amounts of 0.001 to about 0.1 percent, based on the total weight ofthe coating formulation into which they are incorporated.

One suitable formulation for an additive material for a paper webincorporates a water-based coating that is employed in liquid form, andthat coating is an adhesive formulation of R. J. Reynolds TobaccoCompany used as a cigarette seam adhesive and designated as CS-1242. TheCS-1242 formulation is a water emulsion-based adhesive consisting ofabout 87 to about 88 weight percent ethylene vinyl acetate copolymeremulsion sold under the designation Resyn 32-0272 by National Starch &Chemical Company, and about 12 to about 13 weight percent adhesiveconcentrate stabilizer of R. J. Reynolds Tobacco Company known as AC-9.The AC-9 adhesive concentrate stabilizer consists of about 92 weightpercent water and about 8 weight percent polyvinyl alcohol resinavailable as Celvol 205 from Celanese Chemicals. Such a formulationexhibits a viscosity of about 400 centipoise. If desired, theformulation can contain dyes or pigments for aesthetic purposes or tofacilitate automated inspection of paper wrapping materials to which theformulation is applied. Such a formulation is particularly suitable foruse with an application system of the type described previously withreference to FIGS. 3 and 4.

Another suitable formulation for an additive material for a paper web isa starch-based aqueous formulation. A representative formulationincludes about 10 weight percent sodium chloride, about 0.5 weightpercent potassium sorbate, about 35 weight percent oxidized tapiocastarch available as Flo-Max 8 from National Starch & Chemical Company,about 20 weight percent calcium carbonate, and about 34.5 weight percentwater. Such a formulation exhibits a viscosity of about 1,000centipoise. If desired, the formulation can contain dyes or pigments foraesthetic purposes or to facilitate automated inspection of paperwrapping materials to which the formulation is applied. Such aformulation is particularly suitable for use with an application systemof the type described previously with reference to FIGS. 3 and 4.

Another suitable formulation for an additive material for a paper web isa starch-based aqueous formulation. A representative formulationincludes about 5 weight percent sodium chloride, about 0.5 weightpercent potassium sorbate, about 49.8 weight percent oxidized tapiocastarch available as Flo-Max 8 from National Starch & Chemical Company,and about 44.7 weight percent water. Preferably, the mixture is heatedat an elevated temperature (e.g., about 170° F.) for a period of time(e.g., about 10 minutes) sufficient to result in the formation of adesirable paste. Such a formulation exhibits a viscosity in the range ofabout 200,000 centipoise to about 2,000,000 centipoise. The viscosity ofsuch a formulation increases over time after initial manufacture. Ifdesired, the formulation can contain dyes or pigments for aestheticpurposes or to facilitate automated inspection of paper wrappingmaterials to which the formulation is applied. Such a formulation isparticularly suitable for use with an application system of the typedescribed previously with reference to FIGS. 5 through 7.

Another suitable formulation for an additive material for a paper web isa starch-based aqueous formulation. A representative formulationincludes about 10 weight percent sodium chloride, about 0.5 weightpercent potassium sorbate, about 40 weight percent oxidized tapiocastarch available as Flo-Max 8 from National Starch & Chemical Company,and about 49.5 weight percent water. Preferably, the mixture is heatedat an elevated temperature (e.g., about 170° F.) for a period of time(e.g., about 10 minutes) sufficient to result in the formation of adesirable paste. After manufacture and storage, such a formulationexhibits a viscosity in the range of about 200,000 centipoise to about2,000,000 centipoise. The viscosity of such a formulation graduallyincreases over time after initial manufacture. If desired, theformulation can contain dyes or pigments for aesthetic purposes or tofacilitate automated inspection of paper wrapping materials to which theformulation is applied. Such a formulation is particularly suitable foruse with an application system of the type described previously withreference to FIGS. 5 through 7.

For off-line printing, representative types of printers are those thatare available as Scitex Grandject V Professional Printer from ScitexCorporation Ltd. Off-line type printing applications also are set forthin U.S. patent application Ser. No. 10/303,648, filed Nov. 25, 2002.

The amount of coating formulation that is applied to the paper wrappingmaterial can vary. Typically, coating of the wrapping material providesa coated wrapping material having an overall dry basis weight (i.e., thebasis weight of the whole wrapping material, including coated anduncoated regions) of at least about 1.05 times, often at least about 1.1times, and frequently at least about 1.2 times, that of the dry basisweight of that wrapping material prior to the application of coatingthereto. Typically, coating of the wrapping material provides a coatedpaper having an overall dry basis weight of not more about 1.4 times,and often not more than about 1.3 times, that of the dry basis weight ofthe wrapping material that has the coating applied thereto. Typicaloverall dry basis weights of those wrapping materials are about 20 g/m²to about 40 g/m²; preferably about 25 g/m² to about 35 g/m². Forexample, a paper wrapping material having a dry basis weight of about 25g/m² can be coated in accordance with the present invention to have aresulting overall dry basis weight of about 26.5 g/m² to about 35 g/m²,and often about 28 g/m² to about 32 g/m².

The dry weights of the coated regions of wrapping material of thepresent invention can vary. For wrapping materials that are used for themanufacture of cigarettes designed to meet certain cigarette extinctiontest criteria, it is desirable that the wrapping materials havesufficient coating formulation applied thereto to in the form ofappropriately shaped and spaced bands in order that the dry weight ofadditive material applied to those wrapping materials totals at leastabout 1 pound/ream, often at least about 2 pounds/ream, and frequentlyat least about 3 pounds/ream; while the total dry weight of that appliedadditive material normally does not exceed about 10 pounds/ream.

Typical coated regions of paper wrapping materials of the presentinvention that are suitable for use as the circumscribing wrappers oftobacco rods for cigarettes have inherent porosities that can vary.Typically, the inherent porosities of the coated regions of the wrappingmaterials are less than about 8.5 CORESTA units, usually are less thanabout 8 CORESTA units, often are less than about 7 CORESTA units, andfrequently are less than about 6 CORESTA units. Typically, the inherentporosities of the coated regions of the wrapping materials are at leastabout 0.1 CORESTA unit, usually are at least about 0.5 CORESTA unit,often are at least about 1 CORESTA unit. Preferably, the inherentporosities of the coated regions of the wrapping materials, particularlythose wrapping materials that are used for the manufacture of cigarettesdesigned to meet certain cigarette extinction test criteria, are betweenabout 0.1 CORESTA unit and about 4 CORESTA units.

The paper wrapping material of the present invention can have can becoated in patterns having predetermined shapes. The coating can have theform of cross directional lines or bands (including those that areperpendicular to the longitudinal axis of the wrapping material),stripes, grids, longitudinally extending lines, circles, hollow circles,dots, ovals, checks, spirals, swirls, helical bands, diagonally crossinglines or bands, triangles, hexagonals, honeycombs, ladder-type shapes,“zig-zag” shaped stripes or bands, sinusoidal shaped stripes or bands,square wave shaped stripes or bands, patterns composed of coated regionsthat are generally “C” or “U” shaped, patterns composed of coatedregions that are generally “E” shaped, patterns composed of coatedregions that are generally “S” shaped, patterns composed of coatedregions that are generally “T” shaped, patterns composed of coatedregions that are generally “V” shaped, patterns composed of coatedregions that are generally “W” shaped, patterns composed of coatedregions that are generally “X” shaped, patterns composed of coatedregions that are generally “Z” shaped, or other desired shapes.Combinations of the foregoing shapes also can used to provide thedesired pattern.

The relative sizes or dimensions of the various shapes and designs canbe selected as desired. For example, shapes of coated regions,compositions of the coating formulations, or amounts or concentrationsof coating materials, can change over the length of the wrappingmaterial. The relative positioning of the printed regions can beselected as desired. For example, wrapping materials that are used forthe production of cigarettes designed to meet certain cigaretteextinction test criteria, the pattern most preferably has the form ofspaced continuous bands that are aligned transversely or crossdirectionally to the longitudinal axis of the wrapping material.However, cigarettes can be manufactured from wrapping materialspossessing discontinuous bands positioned in a spaced apartrelationship. For wrapping materials of those cigarettes, it is mostpreferred that discontinuous bands (e.g., bands that are composed of apattern, such as a series of dots, grids or stripes) cover at leastabout 70 percent of the surface of the band area or region of thewrapping material.

Preferred wrapping materials possess coatings in the form of bands thatextend across the wrapping material, generally perpendicular to thelongitudinal axis of the wrapping material. The widths of the individualbands can vary, as well as the spacings between those bands. Typically,those bands have widths of at least about 0.5 mm, usually at least about1 mm, frequently at least about 2 mm, and most preferably at least about3 mm. Often, those bands have widths of up to about 10 mm, typically upto about 8 mm, and usually up to about 7 mm. Preferred bands have widthsof about 4 mm to about 7 mm. Such bands can be spaced apart such thatthe spacing between the bands is at least about 10 mm; often at leastabout 15 mm, frequently at least about 20 mm, often at least about 25mm, in certain instances at least about 30 mm, and on occasion at leastabout 35 mm; but such spacing usually does not exceed about 50 mm.

Paper wrapping materials of the present invention are useful ascomponents of smoking articles such as cigarettes. Preferably, one layerof the wrapping material of the present invention is used as thewrapping material circumscribing the smokable material, and therebyforming the tobacco rod of a cigarette. In one regard, it is preferablethat the wrapping material possesses the coated regions located on the“wire” side thereof, and the “wire” side of that wrapping material formsthe inner surface of the circumscribing wrapping material of the tobaccorod. Typically, the “felt” side of the wrapping material is used as thevisible outer surface of the tobacco rod. The terms “wire side” and“felt side” in referring to the major surfaces of paper sheet arereadily understood as terms of art to those skilled in the art of paperand cigarette manufacture.

Cigarettes of the present invention can be manufactured from a varietyof components, and can have a wide range of formats and configurations.Typical cigarettes of the present invention having cross directionalbands applied to the wrapping materials of the tobacco rods of thosecigarettes have static burn rates (i.e., burn rates of those cigarettesunder non-puffing conditions) of about 50 to about 60 mg tobacco rodweight per minute, in the non-banded regions of those cigarettes.Typical cigarettes of the present invention having cross directionalbands applied to the wrapping materials of the tobacco rods of thosecigarettes have static burn rates (i.e., burn rates of those cigarettesunder non-puffing conditions) of less than about 50 mg tobacco rodweight per minute, preferably about 40 to about 45 mg tobacco rod weightper minute, in the banded regions of those cigarettes.

The smokable materials used for the manufacture of cigarettes of thepresent invention can vary. The smokable material typically consistsprimarily of tobacco, and it is preferred that the smokable material bevirtually all tobacco. Descriptions of various types of tobaccos,growing practices, harvesting practices and curing practices are set forin Tobacco Production, Chemistry and Technology, Davis et al. (Eds.)(1999). The tobacco normally is used in cut filler form (e.g., shreds orstrands of tobacco filler cut into widths of about 1/10 inch to about1/60 inch, preferably about 1/20 inch to about 1/35 inch, and in lengthsof about ¼ inch to about 3 inches). The amount of tobacco fillernormally used within a cigarette ranges from about 0.6 g to about 1 g.The tobacco filler normally is employed so as to filler the tobacco rodat a packing density of about 100 mg/cm³ to about 300 mg/cm³, and oftenabout 150 mg/cm³ to about 275 mg/cm³. Tobaccos can have a processedform, such as processed tobacco stems (e.g., cut-rolled or cut-puffedstems), volume expanded tobacco (e.g., puffed tobacco, such as propaneexpanded tobacco and dry ice expanded tobacco (DIET)), or reconstitutedtobacco (e.g., reconstituted tobaccos manufactured using paper-makingtype or cast sheet type processes).

Typically, tobacco materials for cigarette manufacture are used in aso-called “blended” form. For example, certain popular tobacco blends,commonly referred to as “American blends,” comprise mixtures offlue-cured tobacco, burley tobacco and Oriental tobacco, and in manycases, certain processed tobaccos, such as reconstituted tobacco andprocessed tobacco stems. The precise amount of each type of tobaccowithin a tobacco blend used for the manufacture of a particularcigarette brand varies from brand to brand. See, for example, TobaccoEncyclopedia, Voges (Ed.) p. 44-45 (1984), Browne, The Design ofCigarettes, 3^(rd) Ed., p. 43 (1990) and Tobacco Production, Chemistryand Technology, Davis et al. (Eds.) p. 346 (1999). In addition, thesmokable material can be cased and/or top dressed; and/or at least oneflavor component can be incorporated within the side seam adhesiveapplied to the wrapping material during tobacco rod manufacture. See,for example, U.S. patent application Ser. No. 10/303,648, filed Nov. 25,2002.

Cigarette wrapping materials manufactured in accordance with the presentinvention can be used to manufacture a wide variety of cigarettes.Exemplary cigarettes, and exemplary components, parameters andspecifications thereof, are of the type set forth in U.S. Pat. No.4,924,888 to Perfetti et al.; U.S. Pat. No. 5,056,537 to Brown et al.;U.S. Pat. No. 5,220,930 to Gentry; and U.S. Pat. No. 5,360,023 toBlakely et al.; PCT WO 02/37990; US Patent Application 2002/0166563 andSer. No. 10/285,395, filed Oct. 31, 2002; and Bombick et al., Fund.Appl. Toxicol., 39, p. 11-17 (1997); which are incorporated herein byreference.

There are several factors that determine a specific coating pattern fora wrapping material of the present invention. It is desirable that thecomponents of the coating formulations applied to wrapping materials notadversely affect to any significant degree (i) the appearance ofcigarettes manufactured from those wrapping materials, (ii) the natureor quality of the smoke generated by those cigarettes, (iii) thedesirable burn characteristics of those cigarettes, or (iv) thedesirable performance characteristics of those cigarettes. It also isdesirable that wrapping materials having coating formulations appliedthereto not introduce undesirable off-taste, or otherwise adverselyaffect the sensory characteristics of the smoke generated by cigarettesmanufactured using those wrapping materials. In addition, preferredcigarettes of the present invention do not have a tendency to undergopremature extinction, such as when lit cigarettes are held in thesmoker's hand or when placed in an ashtray for a brief period of time.

For an exemplary full flavor cigarette having a tobacco rod length ofabout 63 mm and a filter element length of about 21 mm, crossdirectional bands of about 6 mm width can be spaced at about 20 mmintervals on the wrapping materials used to manufacture thosecigarettes. Alternatively, for those types of cigarettes, bands of about4 mm width can be spaced at about 22 mm intervals on the wrappingmaterials used to manufacture those cigarettes. Alternatively, for thosetypes of cigarettes, bands of about 6 mm width can be spaced at about 39mm intervals. For an exemplary full flavor cigarette having a tobaccorod length of about 70 mm and a filter element length of about 30 mm,cross directional bands of about 6 mm width can be spaced at about 44 mmintervals on the wrapping materials used to manufacture thosecigarettes. For an exemplary ultra low tar cigarette having a tobaccorod length of about 57 mm and a filter element length of about 27 mm,cross directional bands of about 7 mm width can be spaced at about 20 mmintervals. Alternatively, for those types of cigarettes, bands of about6 mm width can be spaced at about 33 mm intervals, or at about 39 mmintervals, on the wrapping materials used to manufacture thosecigarettes. For an exemplary ultra low tar cigarette having a tobaccorod length of about 68 mm and a filter element length of about 31 mm,cross directional bands of about 6 mm width can be spaced at about 44 mmintervals on the wrapping materials used to manufacture thosecigarettes. Full flavor cigarettes are classified as those that yieldabout 14 mg or more of FTC “tar.” Ultra low tar cigarettes areclassified as those that yield less than about 7 mg of FTC “tar.” Thosecigarettes, have tobacco rods having appropriate wrapping materialspossessing bands composed of appropriate amounts of appropriatecomponents have the ability to meet the aforementioned cigaretteextinction criteria.

Certain preferred paper wrapping materials used in carrying out thepresent invention are useful for the manufacture of cigarettes designedto exhibit reduced ignition propensity. That is, cigarettesincorporating certain wrapping materials, when placed on a flammablesubstrate, tend to self extinguish before burning that substrate. Ofparticular interest are those cigarettes possessing tobacco rodsmanufactured using appropriate wrapping materials possessing bandscomposed of appropriate amounts of appropriate components so as to havethe ability to meet certain cigarette extinction criteria.

Cigarettes designed to meet certain cigarette extinction test criteriacan be produced from wrapping materials of the present invention. Bandedregions on a wrapping material are produced using additive materialsthat are effective in reducing the inherent porosity of the wrappingmaterial in those regions. Film-forming materials and fillers applied tothe wrapping material in those banded regions are effective inincreasing the weight of the wrapping material in those regions. Fillermaterials that are applied to the wrapping material in those bandedregions are effective in decreasing the burn rate of the wrappingmaterials in those regions. Typically, when wrapping materials ofrelatively high inherent porosity are used to manufacture cigarettes,those wrapping materials possess relatively high weight bands thatintroduce a relatively low inherent porosity to the banded regions.Film-forming materials have a tendency to reduce the porosity of thewrapping material, whether or not those materials are used inconjunction with fillers. However, coatings that combine porosityreduction with added coating weight to wrapping materials also areeffective in facilitating extinction of cigarettes manufactured fromthose wrapping materials. Low porosity in selected regions of a wrappingmaterial tends to cause a lit cigarette to extinguish due to thedecrease in access to oxygen for combustion for the smokable materialwithin that wrapping material. Increased weight of the wrapping materialalso tends to cause lit cigarette incorporating that wrapping materialto extinguish. As the inherent porosity of the wrapping materialincreases, it also is desirable to (i) select a film-forming material soas to cause a decrease the inherent porosity of the coated region of thewrapping material and/or (ii) provide a coating that provides arelatively large amount of added weight to the coated region of thewrapping material.

Certain cigarettes possessing tobacco rods manufactured using certainappropriately treated wrapping materials, when tested using themethodology set forth in the Cigarette Extinction Test Method by theNational Institute of Standards and Technology (NIST), Publication 851(1993) using 10 layers of Whatman No. 2 filter paper, can meet criteriarequiring extinction of greater than about 50 percent, preferablygreater than about 75 percent, and most preferably about 100 percent, ofcigarettes tested. Certain cigarettes possessing tobacco rodsmanufactured using certain appropriately treated wrapping materials,when tested using the methodology set forth in ASTM Designation: E2187-02b using 10 layers of Whatman No. 2 filter paper, also can meetcriteria requiring extinction of greater than about 50 percent,preferably greater than about 75 percent, and most preferably about 100percent, of cigarettes tested.

For cigarettes designed to meet those aforementioned extinctioncriteria, each such cigarette typically possesses at least one bandlocated in a region of its tobacco rod such that the band is capable ofproviding that cigarette with the ability to meet those extinctioncriteria. For a tobacco rod of a particular length incorporating awrapping material possessing bands that are aligned transversely to thelongitudinal axis of the wrapping material in a spaced apartrelationship, the ratio of the length of the tobacco rod to the sum ofthe width of a band and the distance between the bands is 1 to 2,preferably about 1.1 to about 1.4, and most preferably about 1.2.Alternatively, bands can be positioned at virtually identicalpredetermined locations on each rod (e.g., each cigarette can have oneband positioned 20 mm from the lighting end thereof; or each cigarettecan have two bands, one band positioned at 15 mm from the lighting endthereof and the second band positioned at 30 mm from the lighting end).

Representative cigarettes can be manufactured using paper wrappingmaterials that are printed off-line using electrostatic depositiontechniques. A template can be provided on a sheet of multipurposebusiness paper commonly used for office photocopying. A representativetemplate sheet has a size of about 8.5 inches by about 11 inches. Thetemplate is provided as a pattern made up of a series of black bands,each band of 5 mm width and extending 8.5 inches across the width of thetemplate sheet; and successive leading edges of the bands are separatedfrom one another by 25 mm. Onto a similar second sheet of paper aretaped six strips of cigarette paper web. Each strip is about 11 incheslong, and the strips are aligned parallel to one another so that eachstrip covers that second sheet extends along the length of that secondpaper sheet. The cigarette paper that is used to provide those strips isthe type available as Reference No. 456 from Ecusta Corp. The templatesheet is placed on the imaging region of a Canon Imagerunner 400Scopier. The second sheet is placed in the in-feed tray of the copier.The image from the template is copied onto the second sheet so that theimage from the template in copied onto the cigarette paper strips. Assuch, each cigarette paper strip of 11 inch length has a series of blackbands of 5 mm width and the leading edges of those bands are spaced at25 mm, and those bands each extend transversely to the longitudinal axisof that paper strip. The resulting paper strips are used to madehandmade cigarettes, such as cigarettes of the format and configurationof Camel Light 85 brand cigarettes that are manufactured by R. J.Reynolds Tobacco Company. Cigarettes of such a type can have the abilityto consistently meet certain cigarette extinction criteria, such as theCigarette Extinction Test Method by the National Institute of Standardsand Technology (NIST), Publication 851 (1993) using 10 layers of WhatmanNo. 2 filter paper. As such, electrostatic deposition of photocopiertoner material as a plurality of bands on a cigarette paper wrapper, andthe fusing of that deposited toner to that paper, provides a way formanufacturing a cigarette that has a propensity to extinguish such acigarette when the fire cone of that cigarette reached such a band. Thatis, fusion of the plastic-based components of the toner material to thepaper in selected regions provides that paper with a character that hasthe potential to promote extinguishment of a cigarette manufactured fromthat paper (e.g., fusion of plastic-based toner components to the papercan reduce the inherent porosity of that paper in the printed regions).

Although the present invention has been described with reference toparticular embodiments, it should be recognized that these embodimentsare merely illustrative of the principles of the present invention.Those of ordinary skill in the art of smoking article design andmanufacture will appreciate that the various systems, equipment,materials and methods may be constructed and implemented in other waysand embodiments. Accordingly, the description herein should not be readas limiting the present invention, as other embodiments also fall withinthe scope of the present invention.

1-4. (canceled)
 5. A system for inspecting a continuous web of materialcontaining a pattern, comprising: a capacitor detector for receivinginformation from the continuous web and forming electrical signals inresponse thereto; circuitry for processing the electrical signals bydetermining a presence of a pattern on the continuous web and forgenerating output signals; and computing logic for receiving the outputsignals and determining if the pattern represents an undesired pattern.6. The system of claim 5, wherein the circuitry for determining apresence of a pattern on the continuous web comprises circuitry fordetection of absorption information.
 7. The system of claim 5, whereinthe computing logic is provided by a PLC unit.
 8. A method forinspecting a continuous web of material containing a pattern, comprisingthe steps of: sensing capacitance information and forming electricalsignals in response thereto; processing the electrical signals to detecta presence of the pattern on the continuous web and producing outputsignals; and analyzing the output signals to detect an undesired patternon the continuous web.
 9. The method of claim 8, wherein processing theelectrical signals to detect a presence of the pattern on the continuousweb and producing output signals further comprises detecting absorptioninformation.
 10. The method of claim 8, wherein the output signals areanalyzed using a PLC unit.
 11. The system of claim 5, further comprisinga means for rejecting a portion of the continuous web having theundesired pattern.
 12. The system of claim 6, wherein the circuitry fordetection of absorption information comprises circuitry for detection ofinformation related to absorption of radiation.
 13. The system of claim5, wherein the pattern comprises an additive material applied at acontrolled location on the continuous web of material.
 14. The system ofclaim 13, wherein the controlled location of additive material comprisesspaced apart bands.
 15. The system of claim 14, wherein the spaced apartbands are aligned transverse to a longitudinal axis of the continuousweb of material.
 16. The system of claim 13, wherein the additivematerial comprises a cigarette burn control agent.
 17. The system ofclaim 14, wherein one of the output signals comprises a signalrepresentative of a level of additive material in one of the bands. 18.The system of claim 5, wherein the computing logic comprises a means forreceiving an input signal that corresponds to a speed of the continuousweb of material.
 19. The system of claim 5, wherein the continuous webis disposed on an automated cigarette making machine comprising a meansfor controlling the rate of supply of the continuous web; a means forproviding a continuous cigarette rod by wrapping a tobacco filler in thecontinuous web; a means for controlling a speed of formation of thecontinuous cigarette rod; a means for controlling a location of anapplication of an additive material to the continuous web to provide apattern of the application; and a means for cutting the continuouscigarette rod into a plurality of cigarette rods of predeterminedlengths, each cigarette rod being cut at a controlled location.
 20. Thesystem of claim 19, wherein the means for controlling the location of anapplication of an additive material to the continuous web furthercomprises a means for controlling the location of the additive materialapplication on the continuous web relative to the location at which oneof the plurality of cigarette rods is cut.
 21. The system of claim 19,wherein the means for controlling the location of an application of anadditive material to the continuous web further comprises a means forcontrolling the location of the additive material application relativeto a length of travel of the continuous web after the additive materialis applied and prior to cutting the continuous cigarette rod.
 22. Thesystem of claim 21, wherein the length of travel of the continuous webafter the additive material is applied comprises an adjusted length oftravel.
 23. The method of claim 8, further comprising rejecting aportion of the continuous web having the undesired pattern.
 24. Themethod of claim 9, wherein the detecting of absorption informationcomprises detecting information related to absorption of radiation. 25.The method of claim 8, further comprising controlling a location on thecontinuous web of material at which an additive material is applied toform the pattern.
 26. The method of claim 8, wherein the patterncomprises spaced apart bands.
 27. The method of claim 26, wherein thespaced apart bands are aligned transverse to a longitudinal axis of thecontinuous web of material.
 28. The method of claim 25, wherein theadditive material comprises a cigarette burn control agent.
 29. Themethod of claim 26, wherein one of the output signals comprises a signalrepresentative of a level of additive material in one of the bands. 30.The method of claim 8, wherein the analyzing the output signals furthercomprises receiving and analyzing an input signal that corresponds to aspeed of the continuous web of material.
 31. The method of claim 8,wherein the continuous web is utilized in an automated cigarette makingmachine to manufacture cigarettes by controlling the rate of supply ofthe continuous web; providing a continuous cigarette rod by wrapping atobacco filler in the continuous web; controlling a speed of formationof the continuous cigarette rod; controlling a location of anapplication of an additive material to the continuous web to provide apattern of the application; and cutting the continuous cigarette rodinto a plurality of cigarette rods of predetermined lengths, eachcigarette rod being cut at a controlled location.
 32. The method ofclaim 31, wherein the controlling the location of an application of anadditive material to the continuous web further comprises controllingthe location of the additive material application on the continuous webrelative to the location at which one of the plurality of cigarette rodsis cut.
 33. The method of claim 31, wherein the controlling the locationof an application of an additive material to the continuous web furthercomprises controlling the location of the additive material applicationrelative to a length of travel of the continuous web after the additivematerial is applied and prior to cutting the continuous cigarette rod.34. The method of claim 33, wherein the length of travel of thecontinuous web after the additive material is applied comprises anadjusted length of travel.